Electric motor/generator

ABSTRACT

Certain embodiments are directed to devices, methods, and/or systems that use electrical machines. For example, certain embodiments are directed to an electrical machine comprising: at least one stator at least one module, the at least one module comprising at least one electromagnetic coil and at least one switch, the at least one module being attached to the at least one stator; at least one rotor with a plurality of magnets attached to the at least one rotor, wherein the at least one module is in spaced relation to the plurality of the magnets; and the at least one rotor being in a rotational relationship with the at least one stator, wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; and wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, or combinations thereof. Other embodiments are also disclosed.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is the National Phase application of InternationalApplication No. PCT/AU2012/000655, filed Jun. 8, 2012, which designatesthe United States and was published in English, and further claimspriority to Australian Provisional Application No. 2011902310, filedJun. 10, 2011. The foregoing related applications, in their entirety,are incorporated herein by reference in their entirety.

FIELD

This disclosure relates generally electric motors/generators adapted forvarious applications as well as to related methods and/or systems.Certain embodiments of the present disclosure relate to electricmotors/generators which are: 1) reversible, 2) able to efficientlyproduce high torque in portions of the power and/or RPM range, 3) ableto efficiently produced power in portions of the power and/or RPM range,4) able to efficiently produce high torque substantially throughout thewhole of a defined extended power and/or RPM range, 5) able toefficiently produce power substantially throughout the whole of adefined extended power and/or RPM range, 6) are compact, 8) are modular,or 7) combinations thereof. Certain embodiments are able to be employed,for example, as direct-drive wheel motors, self propelled devices, pumpsand/or power generation.

BACKGROUND

The use of electric motors/generators in a number of application areasis known. For example, in self propelled devices, pumps, and/or powergeneration. Traditional electric motors/generators typically workreasonable well at particular speeds and power requirements. However, asthe speed or power output is varied the efficiency of these traditionalmotors/generators drops. To ensure that the device keeps operating athigh efficiency most devices are often run at higher speeds even whenless would suffice, wasting energy, or are coupled to expensive andheavy transmission systems which require ongoing maintenance and greatlyincrease the number of moving parts increasing the risk of failure.

Modifying existing motor drive systems such that they are capable ofAdjustable Speed Drive (ASD) can introduce energy savings depending onthe application. However, adding ADS to traditional motors is anexpensive exercise. The power supply's frequency has to be modified,requiring high current switching, which use large and expensiveelectronic switches. Further once the speed of the motor is adjusted themotor may no longer be operating at its peak efficiency therefore theenergy savings of running the motor slower may be offset by running themotor in a region that is less efficient.

Various configurations of traction electric motors are known. However,for many applications such motors tend to have excessive weight andbulk. Also known is the use of disk-shaped wheel motors, located at orwithin a wheel, and driving directly. At present, the majority oftraction motors used, for example, in hybrid electric vehicles (HEV) andelectric vehicles (EV) are interior permanent magnet synchronousmachines. In common with other synchronous designs, these may sufferfrom conduction and magnetic losses and heat generation during highpower operation. Rotor cooling is more difficult than with brushlessdirect-current motors and peak point efficiency is generally lower.Generally speaking, induction machines are more difficult to control,the control laws being more complex and less amenable to modelling.Achieving stability over a suitable torque-speed range and controllingtemperature is more difficult than with brushless direct-current motors.Induction machines and switched-reluctance machines have been used formany years, but require modification to provide suitable optimalperformance in, for example, HEV and EV applications.

In an application such as wind powered electric generation, thesesystems tend to be bulky and costly to repair. They also typicallyrequire a gear box, a motor, an inverter and/or a transformer makingthem fairly complex systems that are subject to greater chances ofmalfunction.

There is a need for improved systems, devices and methods directed toelectric motors/generators. The present disclosure is directed toovercome and/or ameliorate at least one of the disadvantages of theprior art as will become apparent from the discussion herein.

SUMMARY

This summary is meant to be exemplary of certain embodiments. Devices,methods of use, methods of manufacture and/or systems are disclosed inthe specification. Some embodiments may not be disclosed n this summarybut are disclosed in other examples or other portions of thisdisclosure.

Certain embodiments are directed to an electrical machine comprising: atleast one stator at least one module, the at least one module comprisingat least one electromagnetic coil and at least one switch, the at leastone module being attached to the at least one stator; at least one rotorwith a plurality of magnets attached to the at least one rotor, whereinthe at least one module is in spaced relation to the plurality of themagnets; and the at least one rotor being in a rotational relationshipwith the at least one stator, wherein the quantity and configuration ofthe at least one module in the electrical machine is determined based inpart on one or more operating parameters; wherein the at least onemodule is capable of being independently controlled; and wherein the atleast one module is capable of being reconfigured based at least in parton one or more of the following: at least one operating parameter duringoperation, at least one performance parameter during operation, orcombinations thereof.

Certain embodiments are directed to an electrical machine comprising: atleast one stator at least one module, the at least one module comprisingat least one electromagnetic coil and at least one switch, the at leastone module being attached to the at least one stator; at least oneslider with a plurality of magnets attached to the at least one slider,wherein the at least one module is in spaced relation to the pluralityof the magnets; and the at least one slider being in a linearrelationship with the at least one stator, wherein the quantity andconfiguration of the at least one module in the electrical machine isdetermined based in part on one or more operating parameters; whereinthe at least one module is capable of being independently controlled;and wherein the at least one module is capable of being reconfiguredbased at least in part on one or more of the following: at least oneoperating parameter during operation, at least one performance parameterduring operation, or combinations thereof.

Certain embodiments are directed to an electrical machine comprising: atleast one stator at least one module, the at least one module comprisingat least one electromagnetic coil and at least one switch, the at leastone module being attached to the at least one stator; at least one rotorwith a plurality of magnets attached to the at least one rotor, whereinthe at least one module is in spaced relation to the plurality of themagnets; and the at least one rotor being in a rotational relationshipwith the at least one stator.

Certain embodiments are directed to an electrical machine comprising: atleast one stator at least one module, the at least one module comprisingat least one electromagnetic coil and at least one switch, the at leastone module being attached to the at least one stator; at least oneslider with a plurality of magnets attached to the at least one slider,wherein the at least one module is in spaced relation to the pluralityof the magnets; and the at least one slider being in a linearrelationship with the at least one stator.

Certain embodiments are directed to a modular, more flexible, moreadaptable electric motor.

Certain embodiments are directed to an electric motor fitted to anelectric car that increases the battery life 10%, 20%, 30%, 40%, 50% ormore.

Certain embodiments are directed to electrical motors that are smallerand/or lighter than similar competing electric motors in the same class.Because of its small size it opens a plethora of options in terms ofwhere to mount the motor. For example in a vehicle the motor could bemounted directly to the wheel. A comparison between the one of theembodiments of the present disclosure and Tesla's current electric motorindicates that certain embodiments have double the power to weightratio. Certain embodiments have a power to weight ratio that is 25%,50%, 100%, 125%, 150%, 200%, 250%, or 300% greater than a brushlesspermanent magnet three phase electrical machine with a substantiallysimilar size and weight.

In certain embodiments, a typical arrangement of brushless, axial-fluxelectric motor comprises one or more rotors in the form of circularplates (these may be substantial flat, disk-shaped) rotationallysupported on a shaft passing through their centres, each the rotorhaving a circular array of high energy permanent magnets embedded aroundits periphery with alternating polarity, the axes of the magnets beingparallel to the shaft; one or more stators in the form of circularplates fixed parallel to the rotors and separated by a small air gap,each the stator having a circular array of electromagnetic coilsembedded around its periphery on the same centre diameter as themagnets; sensing ways (or means) to detect absolute position androtational speed of the rotors; and a control system which, in responseto inputs from the sensing ways (or means) and power and rotationaldirection commands, energises the magnetic coils to attract and repelthe magnets for the purpose of generating rotary motion. One advantageof certain configurations are its high power and/or torque density, themagnitude of torque generated being proportional to the strength of themagnetic flux generated by the coils, the strength of the magnetic fluxof the permanent magnets, the effective diameter of the coil and magnetarrays and the gap between them. At the same time, the use of electroniccommutation to control the current flows to individual stator coilsconfers high energy efficiency over a wide power and RPM range,resulting in essentially flat efficiency curves.

Certain embodiments of the present disclosure are directed toconfigurations of brushless, axial-flux, direct-current electric motorswhich have one or more of the following characteristics: high powerand/or torque densities; which combines rapid acceleration with anextended RPM range; which has low weight and/or compact form, making itsuitable for a variety of applications; which employs complex controlmechanisms (or means) to obtain high efficiency throughout the desiredrange of operational parameters; which has minimal cooling requirements;which is robust and mechanically and electrically reliable; which iscapable of being manufactured through the assembly of standardcomponents in a range of configurations suitable for employment invehicles from automobiles to heavy trucks and machinery; which isadaptable for use as a wind power, tidal power or wave power generatorable to optimise generating efficiency throughout a range of highlyvariable generating conditions and which may be manufactured at acompetitive cost.

According to certain embodiments, a brushless, axial flux,direct-current electric motor comprises: one or more disc-shaped statorsaround the periphery of which a circular array of equally-spaced (orsubstantially equally spaced) electromagnetic coils may be embedded; oneor more disc-shaped rotors around the periphery of which a circulararray of equally-spaced (or substantially equally spaced) magnets may beembedded, the array having the same, or substantially the same centrediameter as that of the electromagnetic coils and the magnets havingalternating pole orientation; the rotors being rotationally supportedparallel (or substantially parallel) to the stators with an air gapbetween them. The central parts of the stators may be cut away to permitthe passage therethrough of a shaft supporting the rotors and thecircuit boards are supported from the stators concentrically with theshaft, the circuit boards may incorporate solid-state switches which maybe activated by command signals from a control system to power theelectromagnetic coils to cause the rotors to rotate. In certainembodiments, one or more sensor may be provided to generate signalsrelating to the absolute and instantaneous positions of the rotors. Incertain embodiments, one or more sensor may be provided to generatesignals relating to the substantially absolute and/or substantiallyinstantaneous positions of the rotors. In certain embodiments, thepermanent magnets are sufficiently powerful and may be of the rare earthtype and the electromagnetic coils are of a form generating high levelsof magnetic flux, but having low magnetic reluctance permitting rapidswitching or reversal of polarity. In certain embodiments, the permanentmagnets may be sufficiently powerful and/or may be of the rare earthtype wherein the one or more of the electromagnetic coils are of a formgenerating sufficiently high levels of magnetic flux. In certainembodiments, permanent magnets and/or electromagnetic coils ofconventional form are optionally employed in electric motors for lowercost applications or those required to meet different operationalparameters. Electrical current may be supplied to the solid-stateswitches via the structure of the stators, thereby permitting a heavycurrent flow to the solid-state switches with minimal losses, and theembedding of the electromagnetic coils in the stators permits efficientconductive cooling. In certain embodiments, electrical current may besupplied to the solid-state switches via the structure of the stators,thereby permitting a suitably heavy current flow to one or more of thesolid-state switches with suitably minimal losses, and the embedding ofthe electromagnetic coils in the stators permits suitable efficientconductive cooling. The positioning of the switches immediately adjacentthe electromagnetic coils provides conduction paths of low resistancewith minimal losses. In certain embodiments, the positioning of theswitches adjacent (or substantially adjacent) one or more of theelectromagnetic coils provides conduction paths of suitably lowresistance with suitably minimal losses. In certain embodiments, thecombination of one or more of the features provides an electric motor ofhigh power density and/or one able to operate efficiently over anextended RPM range. In certain embodiments, the control system of thedirect current electric motor may be made to be continuously adaptive,utilising complex logic to determine the most efficient mode ofoperation in relation to prevailing operational parameters. In certainembodiments, the control system of the direct current electrical machinemay be sufficiently continuously (or substantially continuously)adaptive, utilising logic to determine or estimate the appropriatelyefficient mode of operation in relation to one or more prevailingoperational parameters.

BRIEF DESCRIPTION OF THE FIGURES

These and other features, aspects, and advantages of the presentdisclosure will become better understood with regard to the followingdescription, appended claims, and accompanying figures where:

FIG. 1 is a longitudinal cross-sectional view through an electric motormade in accordance with certain embodiments of the present disclosure.

FIG. 2 is an incomplete face view of a first side of a stator of theelectric motor of FIG. 1.

FIG. 3 is an incomplete face view of a second side of a stator of theelectric motor of FIG. 1.

FIG. 4 is a partially cut-away view of the electromagnetic coils,according to certain embodiments of the present disclosure.

FIG. 5 is a face view of a rotor of the electric motor of FIG. 1,according to certain embodiments.

FIG. 6 is a face view of a rotor of the electric motor of FIG. 1,according to certain embodiments.

FIG. 7 is a schematic diagram of the electrical and electronic systemsof the electric motor of FIG. 1.

FIG. 8 illustrates a gap in the conductive region of the stator,according to certain embodiments.

FIG. 9 illustrates a cross section view of a rotor platter configurationaccording to certain embodiments.

FIG. 10 illustrates a cross section view of two rotor plattersconfiguration according to certain embodiments.

FIG. 11 illustrates a cross section view of a three rotor plattersconfiguration according to certain embodiments.

FIG. 12 shows a schematic top view of a rotor platter and coilconfiguration, according to certain embodiments.

FIG. 13 shows a perspective view of the configuration of FIG. 12.

FIG. 14 is a render of an electrical machine built with the exemplaryconfiguration illustrated in FIGS. 12 and 13.

FIG. 15 is a side view of a double sided linear arrangement of a platterand coil configuration, according to certain embodiments. This figureshows a layout of the magnets in relation to the coils when in a linearconfiguration.

FIG. 16 is a bottom view of a single sided linear arrangement of aplatter and coil configuration, according to certain embodiments.Included in this figure are the stator and slider, thus displaying theirdirection of motion relative to each other.

FIG. 17 is a cross section side view of the single sided lineararrangement of the platter and coil configuration, shown in FIG. 16.This figure shows the geometric positioning of the coils within thestator.

FIG. 18 shows in side view an example of the magnetic field linesbetween two magnetic rotors and one coil platter, without end caps,according to certain embodiments.

FIG. 19 shows in side view an example of the magnetic field linesbetween two magnetic rotors and one coil platter, with ferrous steel endcaps, according to certain embodiments.

FIG. 20 shows an example of the magnetic field lines between twomagnetic rotors and one coil platter, with the top rotor consisting ofmagnets aligned in a Halbach array, according to certain embodiments.

FIG. 21 illustrates an isometric view of a configuration where the coilis mounted on a circuit board, according to certain embodiments.

FIG. 22 illustrates an isometric view of the circuit boards illustratedin FIG. 21 mounted in an electrical machine, according to certainembodiments.

FIG. 23 shows an example of a H-bridge switch topology that may be usedwith certain embodiments.

FIG. 24 illustrates an exemplary Motor Control Unit (MCU), Coil ControlUnit (CCU), coil driver controller architecture, according to certainembodiments.

FIG. 25 illustrates a CCU's architecture, according to certainembodiments.

FIG. 26 shows one or more individual MCUs and CCUs in a 1:1:1configuration, according to certain embodiments.

FIG. 27 shows switches controlled by one CCU, with the one CCU beingcontrolled by one or more MCU in a 1:1:n configuration, according tocertain embodiments.

FIG. 28 shows switches controlled by CCUs, with the CCUs beingcontrolled by one or more MCU in a 1:m:n configuration, according tocertain embodiments.

FIG. 29 shows an exemplary controller configurations, whereby switchesare controlled directly by one or more MCUs in a 1:n configuration

FIG. 30 illustrates a CCU without the need for a master controller,according to certain embodiments.

FIG. 31 shows a configuration where a single motor control unit isconnected to a common communication bus, which is connected to one ormore of the coil control units, according to certain embodiments.

FIG. 32 shows a configuration where multiple motor control units areconnected to a common communication bus, which is connected to one moreeach of the coil control units, according to certain embodiments.

FIG. 33 illustrates a configuration wherein each coil control unit isconnected directly to some or all of all other coil control, accordingto certain embodiments.

FIG. 34 illustrates a configuration wherein a central communication bus(token ring) is used, according to certain embodiments.

FIG. 35 illustrates a configuration with three redundant communicationbuses, according to certain embodiments.

FIG. 36 is a computer rendering of the electrical machine detailed inFIG. 1. Suitable applications include traction motors in vehicle wheelhubs, according to certain embodiments.

FIG. 37 shows a photo of the electrical machine detailed in FIG. 1attached to the suspension system of the existing car design, accordingto certain embodiments.

FIG. 38 shows a photo of the electrical machine in FIG. 37 from adifferent view illustrating the electrical machine fitting inside thewheel hub of the car.

FIG. 39 is a rendering of a gear pump with the electrical machineillustrated in FIG. 22.

FIG. 40 is a photo of a linear solenoid configuration of an electricalmachine, according to certain embodiments.

FIG. 41 is a schematic in top view of a linear solenoid configuration ofan electrical machine, according to certain embodiments.

FIG. 42 is a schematic in partial side view of the linear solenoidconfiguration of FIG. 41.

FIG. 43 is a schematic of a linear generator electrical machine,according to certain embodiments, being applied to harness electricalenergy from waves.

FIG. 44 is a top schematic view of a design for a module that includes aCCU and a coil driver unit, according to certain embodiments.

FIG. 45 is a cut away top view of FIG. 44.

FIG. 46 is a cut away side view of the module in FIG. 44 whichillustrates the internal structure of the module as well as thealignment of the magnets on the rotor.

FIG. 47 is a cut away end view of the module in FIG. 44.

FIG. 48 is an isometric view of a three phase generator, according tocertain embodiment.

FIG. 49 is of a multi platter embodiment, composed by stacking severalof the embodiments shown in FIG. 48.

FIG. 50 is a schematic showing the geometric properties of a magnetshape placed in a circular array, according to certain embodiments.

FIG. 51 is a schematic showing the geometric properties of a circularmagnet shape placed in a circular array, according to certainembodiments.

FIG. 52 is a side view of an electrical machine that is made up of twoelectrical machines that are back to back and share a common rotorshaft, according to certain embodiments.

FIG. 53 is a side view of the electrical machine illustrated in FIG. 52but these embodiments share a common magnet rotor.

FIG. 54 is a graph that shows how the total magnet count decreases asthe number of coil stages increases, according to certain embodiments.

FIG. 55 is a graph torque comparison, according to certain embodiments.

FIG. 56 is a graph comparing the power losses due to electricalresistance of certain embodiments.

DESCRIPTION

The present disclosure will now be described in detail with reference toone or more embodiments, examples of which are illustrated in theaccompanying drawings. The examples and embodiments are provided by wayof explanation and are not to be taken as limiting to the scope of thedisclosure. Furthermore, features illustrated or described as part ofone embodiment may be used by themselves to provide other embodimentsand features illustrated or described as part of one embodiment may beused with one or more other embodiments to provide a furtherembodiments. It will be understood that the present disclosure willcover these variations and embodiments as well as other variationsand/or modifications. It is also to be understood that one or morefeatures of one embodiment may be combinable with one or more featuresof the other embodiments. In addition, a single feature or combinationof features in certain embodiments may constitute additionalembodiments.

The features disclosed in this specification (including accompanyingclaims, abstract, and drawings) may be replaced by alternative featuresserving the same, equivalent or similar purpose, unless expressly statedotherwise. Thus, unless expressly stated otherwise, each featuredisclosed is one example of a generic series of equivalent or similarfeatures.

The subject headings used in the detailed description are included onlyfor the ease of reference of the reader and should not be used to limitthe subject matter found throughout the disclosure or the claims. Thesubject headings should not be used in construing the scope of theclaims or the claim limitations.

Certain embodiments consist of a stator and a rotor which may becontained in an enclosure. The rotor creates a magnetic field in thevicinity of the stator; the stator creates a disturbance in the magneticfield forcing the rotor to move to a position that minimizes thedisturbance in the magnetic field. The rotor may consist of a series ofpermanent magnets attached to a shaft. The stator may consist of aseries of coils, attached to an enclosure. The enclosure may housebearings to ensure that the rotor can rotate to minimize the disturbancein the magnetic field. Certain embodiments are directed to an electricalmachine comprising: at least one rotor, a plurality of magnets used in,or in contact with, the rotor, at least one stator and a plurality ofcoils used in, or in contact with, the stator, wherein the configurationis contain, partially contained within and a enclosure; and a controlelectronics provides individual control over each coil and/or cluster ofcoils generating the disturbances. In certain embodiments, the controlelectronics provides individual control over one or more coils and/orone or more cluster of coils generating the disturbances. In certainembodiments, the control electronics provides individual control over atleast 40%, 50%, 60%, 70% 80%, 90%, 95% or 100% of the coils or at least40%, 50%, 60%, 70% 80%, 90%, 95% or 100% of the cluster of coilsgenerating the disturbances.

Certain embodiments are directed to an electrical machine that providessignificant size, weight reduction, price reduction, or combinationsthereof, while increasing the electrical machine's power output,efficiency, maintainability or combinations thereof. Also disclosed aremethods of using the electrical machine, methods of manufacturing theelectrical machine and/or systems that incorporate the electricalmachine.

Certain embodiments are directed to adaptive magnetic flux arrayswherein the device, methods, and/or systems permit real time, orsubstantially real time, software reconfigurable electricalmotor/generator. The disclosed devices, methods and/or systems may beused as both a motor and a generator may also be referred to as anelectrical machine. One advantage of certain embodiments is the abilityof those embodiments to reconfigure itself in real time, orsubstantially real time, this permits the machine, method and/or systemto find its optimal settings across very wide operating speeds and/orloads. Such flexibility results in energy savings across a plethora ofindustries. Other advantages of certain embodiments disclosed hereinare: reduce cost by reducing the amount of copper in the windings; theamount of electrical steel; the size of the package required to house itor combinations thereof.

For example, the weight of the copper windings in an electrical machineis proportional to the size of current, greater the current the heavierthe wire. This relationship is quadratic, not linear. Certainembodiments effectively divide and conquer this relationship. In certainembodiments each (or one or more) independent coil handles relativelysmall amounts of current. By using numerous small coils, the overallcurrent through each coil (or one or more) remains low, but the totalcurrent for the whole system scales linearly, along with the quantity ofmaterial and/or the cost of the electrical machine. By overcoming thisquadratic relationship much larger electrical machines may be built atmore affordable prices.

For example, a traditional 3 phase 300 kw electrical machine operatingoff a 415 v supply requires a current through each phase of the coil of240 amps. In one exemplary embodiment, the windings are distributedacross 34 coils, the current per coils is 21 amps. To have the same,substantially the same, or similar, resistive power loss through the twoconfigurations, the traditional electrical machine requires about 10times the weight of wire. Certain embodiments are directed to anelectrical machine wherein the resistive power loss is substantially thesame as the resistive power loss of a traditional electrical machine butthe electrical machine requires at least 500, 400, 300, 250, 200, 150,100, 75, 50, 25, 20, 10, or 5 times less weight of wire. Certainembodiments are directed to an electrical machine that usessubstantially less copper wherein the resistive power loss issubstantially the same as the resistive power loss of a similar machinewith fewer coils. The copper saved is proportional to the number ofcoils cn the embodiment contains compared to the number of coilscontained in a comparable machine dn. The potential savings are up to dndivided by cn times the copper. In certain embodiments, the electricalmachine requires between 500 to 100, 100 to 300, 50 to 100, 150 to 250,300 to 250, 225 to 175, 150 to 75, 75 to 50, 50 to 25, 20 to 10, 15 to 5times less the weight heavier of wire as compared with a brushlesspermanent magnet three phase electrical machine with similar power.

In the example, above as there is 10 times less wire, the volume of ironcore required to wrap the wire around is decreased. Subsequently theentire unit can fit into a substantially smaller enclosure furtherreducing the mass of materials. High currents still need to betransferred from the devices power input to the coils. If the body ofthe electrical machine is constructed from a good conductor such asaluminium, the body can be used as the conductor, further reducing themass of materials used. In this example, the exemplary electricalmachine disclosed herein reduces the weight of a 300 kw electricalmachine from many hundreds of kilograms to about 34 kilograms. Certainembodiments disclosed herein provide an electrical machine that mayproduce substantially the same power output of a traditional electricalmachine but with a weight that is reduced by at least 95%, 90%, 85%,80%, 70%, 60%, 50%, 40%, 30%, or 20%. Certain embodiments disclosedherein provide an electrical machine that may produce substantially thesame power output of a traditional electrical machine but with a weightthat is reduced by between 95% to 20%, 90% to 70%, 85% to 60%, 90% to50%, 80% to 40%, 70% to 50%, 60% to 30%, 50% to 20%, 40% to 20%, or 30%to 20%.

Another advantage of certain embodiments is the ability to independentlycontrol each coil, when less torque is required or available, sectionsof the electrical machine may be powered down. In certain embodimentsthe ability to independently control one or more coils, when less torqueis required or available, then sections of the electrical machine may bepowered down. Certain embodiments are directed to an electrical machinewith the ability to independently control one or more coils. Certainembodiments are directed to an electrical machine with the ability toindependently control one or more coils. Certain embodiment are directedto an electrical machine with the ability to independently control atleast 70%, 80%, 90%, 95%, 98% or 100% of one or more coils in aplurality of coils. Certain embodiment are directed to an electricalmachine with between 10 to 100, 20 to 50, 50 to 200, 20 to 60, 30 to 80,or 30 to 60 coils wherein the electrical machine is configured toindependently control at least 70%, 80%, 90%, 95%, 98% or 100% of thecoils. Because certain disclosed embodiments have numerous coils,substantially finer control over optimising the efficiency of themachine is available.

Traditional electrical machines control their peak efficiency by varyingthe timing of the switching between phases of their coils. As the timingis traditionally set at assembly or installation either by the brushesor the frequency of the drive circuit, variations of velocity and powerreduces the peak efficiency of the electrical machine. Another advantageof certain embodiments is that they may be configured to continuouslyoptimize the timing of the coils, this can provide efficiency savings ofup to, for example, 40% when summed over the entire operating region ofa comparatively powered electrical machine. Certain embodiments may beconfigured to optimize the timing of a plurality of coils substantiallycontinuously, sufficiently continuously, continuously, non-continuously,or intermediately. In certain embodiments the ability to optimize thetiming of a plurality of coils substantially continuously, sufficientlycontinuously, continuously, non-continuously, or intermediately providesan efficiency savings of up to 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%,50%, or 60% when summed over the entire operating region of acomparatively powered electrical machine.

In an axial configuration, certain embodiments of the present disclosuremay reduce the total number of permanent magnets by a minimum of 25%.The total saving percentage increases with the number of rotorsrequired. This may be achieved sharing of common rotors, making use ofboth sides of a rotors magnetic fields rather than one. For example, ina two stator, 4 rotor motor, one rotor is eliminated for a saving of25%. For 6 stator, 12 rotor motor, 5 rotors are eliminated for a savingof 41%. In certain embodiments, the total number of permanent magnetsmay be reduced by a minimum of 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%,50%, 55%, 60% or 70% and still provide comparable power output.

Certain embodiments of the present disclosure may accommodate magnets ofvarious shapes. For example, the shape may be a cylinder, cuboid,segmented, trapezoidal or other suitable shapes.

For smooth torque a sinusoidal application of force may be suitable.Through the use of the interleaved coil design of certain disclosedembodiments it is possible to create a smooth sinusoidal output usingcylindrical magnets. A further consequence of the interleaved coildesign is reduced magnet volume. Most axial flux motors use trapezoidalmagnets, which for a given diameter, or trapezoidal height, occupy andrequire more magnetic volume. For a trapezoidal with long edge length40, short 15 and height 25, vs. a circular magnet of diameter 25, avolumetric saving of 29.24% is achieved. Minimal saving occurs when thetrapezoidal shape approaches a square, giving a minimum reduction ofapproximately 21%. Certain embodiments may be configured in a circulararray, or substantially circular array, such that the electrical machinehas one more set of magnets than coils, the coils can be powered in sucha sequence that the torque generated by the electrical machine issufficiently smooth. Ensuring that there is little variation in torqueduring start up ensures smooth acceleration at low speeds. For example,an embodiment that comprises a 17 coil circular array has about 30 timesless variation in torque through a rotation than a 3 phase equivalent.Certain embodiments comprising a plurality of coils in at least onecircular array has 50, 40, 35, 30 25, 20, 15, 10, 5, times lessvariation in torque through a rotation than a 3 phase equivalent.

Magnet Volume Reduction

In regards to efficiency the ideal switching waveform inside a coil is asine wave. The sine wave has only one frequency component, thefundamental frequency, ensuring that higher frequency harmonics may notbe contained in the signal. An ideal square wave may be made up of thefundamental frequency (the frequency of the square wave) plus aninfinite sequence of higher frequency harmonics contained in its Fourierseries. There are a number of drawbacks in terms of high frequencyharmonics. High frequency signals tend to travel along the outer edge ofthe conductor known as the skin effect. The higher the frequency thecloser to the skin the signal travels. The resistance of a wire isproportional to the cross sectional area where the electrons aretravelling. The resistance of the wire is therefore proportional to thefrequency through that wire. Further high frequency signals tend toradiate away from the device causing interference to other devices.These radiated effects need to be contained and filtered to pass CE,FCC, C-tick and other compliance standards. Circular magnets coupledwith the interleaved coil design create a nice sine wave output. Aconsequence of cylindrical magnets is reduced total magnet volume, nowreferring to FIG. 50 we have: Volume of trapezoidal magnet:

${V_{trap} = {\left( \frac{a + b}{2} \right){cd}}};$d=magnet thicknessVolume of circular magnet: V_(circ)=πr²d; Noting: 2r=Cand given the ratio of a:b is sufficient such that the trapzoidalperimeter does not intersect the circular perimeter.Now referring to FIG. 51 we have: Volume saving per coil:

V_(saving) = V_(trap) − V_(circ)$V_{saving} = {{\left( \frac{a + b}{2} \right){cd}} - {{\pi\left( \frac{c}{2} \right)}^{2}d}}$Alternatively:

$V_{{saving}_{\%}} = {{\left( {1 - \frac{Vcirc}{Vtrap}} \right) \times 100} = {\left( {1 - \frac{\pi\; c}{2\left( {a + b} \right)}} \right) \times 100}}$

In certain embodiments, this saving can be substantial, for example ifwe compare two 25 mm thick rotors, one containing a cylindrical magnetof a diameter of 25 mm and once containing a trapezoidal magnet witha=30, b=20, c=25 the material savings in the cylindrical magnet would be21.46%. In certain embodiments, the material savings in the magnetswould be at least 10%, 15%, 20%, 30%, 40%, 50%, or 60%. In certainembodiments, the material savings in the magnets would be between 10% to60%, 15% to 25%, 15% to 40%, 20% to 60%, 20% to 35%, 30% to 60% or 35%to 55%. In certain embodiments, the savings may be calculated asfollows:

$V_{{saving}_{\%}} = {{\left( {1 - \frac{\pi\; 25}{2\left( {30 + 20} \right)}} \right) \times 100} = {{{\left( {1 - \frac{\pi 25}{100}} \right) \times 100}\therefore V_{{saving}_{\%}}} = {21.46\mspace{14mu}(\%)}}}$

In regards to peak power, more power may be transferred in a square wavethan in a sine wave. The effective power that may be imparted into thecoil by a sine wave is 1 divide by a square root of 2 (approximately ⅔)while the effective power of a square wave is 1. In terms of theeffectiveness of the mechanical energy that can be converted by a squarewave vs. a sine wave is dependent at least in part on the design of thecoils and the magnets.

Magnets Saving Through Shared Platter Stacks

In certain embodiments, the device may be extended to provide more powerby connecting two motors back to back as illustrated in FIG. 52. Aweight and/or cost saving may be achieved by sharing of rotors asillustrated in FIG. 53. In this example, the total number of magnets isreduced by sharing the inner rotors, segments 154 and 155, combiningthem into one rotor, segment 158. Further, only the outer platters,segments 156 and 157 require back irons to contain the magnetic fieldinside the device, as opposed to the unshared configuration whichrequires all rotors to be shielded (a total of 4 plates). Typically, theback irons are heavy and thus there is a substantial weight savingthrough sharing inner rotors. Further the device is more compact, savingthe mass of the associated materials. In other words: Total number ofmagnets (unshared): n_(total) _(unshared) =n_(platters)×m; m=number ofmagnets per platterTotal number of magnets (shared centre rotor platter):

$n_{{total}_{shared}} = {\left( {n_{unshared} - \left( {\frac{n_{unshared}}{2} - 1} \right)} \right) \times m}$Left  figure: n_(total_(unshared)) = 4 × 17;Assuming  17  magnets  per  platter n_(total_(unshared)) = 68Right  figure:$n_{{total}_{shared}} = {\left( {4 - \left( {\frac{4}{2} - 1} \right)} \right) \times 17}$n_(total_(shared)) = 51FIG. 54 is a graph that illustrates the reduction in the number ofmagnets when common magnetic rotors are shared between multiple stators.This example is based on rotors with 18 magnets, but the general trendshold true for a range of embodiments. The x axis illustrates the numberof stators, and the Y axis indicates the number of magnets. A comparisonis made between a configuration sharing common internal rotor platters162, to a configuration without shared rotor platters 161. Itillustrates that there are significant saving in the number of magnetsrequired, and thus cost, space and weight savings, when the platters areshared. This saving tends linearly towards almost 50% or more plattersare used.Torque Smoothing

A traditional motor with only a single phase supply is only able toapply peak power to the shaft twice per rotation. A basic comparisonbetween motor configurations may be used by assuming the resultingrotational torque is proportional to the sine of the angular differenceof the coils to the permanent magnets. τα sin(F)

In this exemplary embodiment it is assume that for the number of phasesin a motor, the power applied is constant. As the numbers of phases inthe motor are increased, the power is distributed and applied moreevenly. For a three phase motor, it provides maximum power and torque tothe shaft 6 times per rotation. Its maximum instantaneous power is lessthan the single phase motor. Since certain embodiments of the presentdisclosure may have at least 17 to 1024 independently controllablephases. Certain embodiments may have between 17 to 1021, 19 to 1181, 29to 109, 53 to 127, 89 to 257, 211 to 331, 199, to 577, 433 to 751, 577to 1051, 613 to 757, 619 to 919, 773 to 857, 787 1021, or 811 to 1283independently controllable phases. Certain embodiments may have between10 to 1050, 20 to 40, 30 to 50, 50 to 1200, 75 to 150, 200 to 500, 400to 1200, 600 to 900, or 700 to 1100. This distributes power more evenlythroughout a single rotation and results in smooth torque being appliedto a load.

A simple comparison of maximum producible instantaneous torquethroughout a motors rotation is presented in FIG. 55. This graphdemonstrates the relative torque on the y axis a similarly rated singlephase 164, three phase 165 and 17 phase electrical machine 163. The xaxis indicates the motors angular position over a range of 0 to 360degrees. Because the 17 phase electrical machine configurationeffectively has more phases than the other electrical machineconfigurations it has a more constant producible torque and a muchsmoother torque without any smart software control or otherwisecontrolling the electrical machine. In certain applications theachievable torque may be even smoother with the aid of softwarealgorithms and feedback control. Although the peak instantaneous torqueproducible of the other motor configurations is larger than that of the17 phase electrical machine, the power being delivered is approximatelythe same, the power from the other motor types is applied largely inshort bursts making it harder to control.

One of the features of certain disclosed embodiments is that there maybe an offset between a coil and a pair of magnets, i.e.: if there is ncoils and n+1 magnets, then the magnets may not be perfectly align withthe coils. This ensures that the electrical machine of these embodimentswill be able to turn on at least one coil to turn the machine, whilealso having the effect of smoothing the torque applied to the machine.Because there is an offset between coils and magnets, it has the effectof making the motor into an n phase motor. In a traditional electricmotor, when less power is required, the amount of power applied in eachrotation to the motor is reduced. This reduces the produced torquenon-linearly. In certain disclosed embodiments as one or more coils (oreach coil) are able to be digitally controlled, coils that produce lessoptimal instantaneous torque onto their corresponding magnet may beturned off. This causes a non-linear reduction in torque with respect toreduction in power.

FIG. 56 illustrates the non-linear increase in heat generated due toresistive losses as power is increased in different electrical machineswith different number of phases, with comparative power between theelectrical machines. Certain embodiments of a 17 phase machine 166 arecompared to a three phase 167 and two phase 168 machines withsubstantially identical input power. The x axis is a comparative axis ofthe percentage of power and the y axis is the power loss throughresistive heating. This demonstrates the superior power handlingcapability of the certain embodiments disclosed herein, if the power tothe coils is linearly adjusted from 0 to 100% which is possible due todirect microprocessor control. Having more phases for power divides thecurrent supplied between each of the phases substantially equally and assuch the power loss due to resistive heating is non-linearly reduced bythe factor of the number of phases, as power loss is typically equal tothe current squared times the resistance of its conductor. This meansthat to deliver the same power as other motor types certain embodimentsmay be much smaller and/or lighter than existing motor types and/or becapable of handling higher power requirements and outputs.

Torque Smoothing Vs. Operating Frequency

Because torque applied at any instantaneous moment is a function of theangle of the motor platter, the apparent torque smoothing will vary withfrequency, i.e.: as the motor speeds up, the variations in torque willbecome less obvious. Since certain embodiments may be operated with nphases, one or more coils (or each coil) may operate n times faster thanit would on a single phase motor. The torque may be further smoothed byusing digital algorithms to limit the maximum power applied to a coil inthe optimal position. This may have the effect of slightly reducing themaximum torque, but would substantial smooth the torque output. FIG. 55shows a graph that demonstrates the superior torque smoothing of certaindigital axial flux motor embodiment compared to some standard motortypes. One of the advantages of the motors in these embodiments is thatit can individually control power to each coil (or one or more coils),allowing it to maintain suitably high output powers and/or torques whilekeeping its n phase torque smoothing characteristics. These embodimentshave the ability to change on the fly, for lower rpm's where torquesmoothing is more important, the motor may intelligently apply asmoothing profile, or a profile for suitable maximum torque and/oroutput power as it is required, or at higher rpm's.

Rotor

Exemplary embodiments of the present disclosure may consist of one ormore rotors. One of their purposes is to create a magnetic field in thevicinity of the electromagnets, such that the stator coils induce torquein the rotor. Magnets may be secured within the rotor via multiplemethods. For example by gluing; clamping (between two or more rotorlayers) and/or interference fit (with the surrounding hole);mechanically fixing (for example, bolted, threaded or other suitableways); welding (when applicable to chosen magnet and/or rotor material);sintering; other effective means or combinations thereof.

The rotor may be constructed from a number of materials. Constructionmaterials chosen for the rotor may vary depending on the application ofthe motor, as well as the chosen magnetic field strength between therotors. In certain embodiments, the chosen material will typically be ofsufficient Young's Modulus (stiffness) to prevent unacceptabledeformation or substantial deformation due to the axial magnetic forcesbetween two separate rotor platters. Materials used may include (but arenot limited to): aluminium; polymers, such as HDPE (High densitypolyethylene); other suitable materials or combinations thereof.

Magnetic Rotors: In certain embodiments, the need for separate magnets(which are then attached to the rotors) may be eliminated (or reduced)through the use of sintering to bond separate magnets and the mechanicalcasing into substantially one structure. A finishing surface may then beapplied (for example, nickel, epoxy) to increase mechanical strengthand/or durability.

Reluctance configuration: In certain embodiments, it is possible for themagnets to be replaced in whole or in part with ferrous strips,resulting in a reluctance motor configuration. Inductance configuration:In certain embodiments, by replacing one or more, a substantial portionof, or all of the magnets in the rotors with coils, the stator coilsmagnetic fields will induce magnetic fields in the rotor coils. Bywiring the rotor coils to their symmetric or offset equivalent coils(with respect to the rotor), opposing magnetic fields may be induced,resulting in rotational forces. Material Reduction: for certainapplications it may be advantageous to reduce the rotational inertia ofthe rotor and/or shaft assembly. To this end the rotor discs may havetheir shape changed to remove excess material which is not necessary tothe mechanical structure of the disk.

Shaft and Spacers: In certain embodiments, the rotor assembly may belocated within or partial within the motor enclosure through the use ofa shaft. This shaft may have a non-uniform diameter such thattranslational movement of the rotor magnet platters in the rotationalaxis of the shaft is reduced, substantially prevented or prevented. Thetranslational forces may be absorbed from the shaft into the casing.Methods include (but not limited to): axial thrust bearings or otherball, pin or conical bearings; interference between shaft and assemblywith low friction surface; the shaft may be of sufficient diameterand/or stiffness such that bending due to magnetic forces between rotorplatters does not occur or is sufficiently reduced. In certainembodiments, the materials that may be used for shafts and/or spacersinclude metals (such as steel, aluminum), polymers or other suitablematerials. Torque transmission: In certain embodiments, once torque isinduced in the rotor it may be transmitted either mechanically throughdirect fixture to a shaft, via magnetic couple to an external magneticplatter, mechanical coupling to a shaft (egg. via a clutch), othersuitable means or combinations thereof. In certain embodiments, it ispossible for the shaft to be removed entirely (or partially) andreplaced with a spacer, or multiple spacers, to separate two or morerotor platters. In these configurations the assembly may be locatedwithin the enclosure through the use of magnetic suspension.Alternatively, in certain embodiments, an annular bearing supporting theouter radial edge of the rotors (or a substantially portion of therotors) may be used. These configurations may or may not use a centrespacer to separate rotors axially, depending on the number of bearingsused.

Magnets

Certain embodiments of the electrical machine disclosed herein mayincorporate different types and/or shapes of magnets. One of thepurposes of the magnets is to induce a magnetic field, through whichsuspended electromagnetic coils can pass (thus inducing kinetic forceson the coils/rotors). Applicable types of magnets include, for example:rare earth magnets including but not limited to Neodymium,Neodymium-boron, Samarium-cobalt alloys or combinations thereof; varioustypes of superconducting magnets; standard and/or permanent magnets madeof materials such as but not limited to Alnico, Bismano, Cunife, Ferico,Heusler, Metglas, and other magnetic alloys or combinations thereof;electromagnets, such as wire coils, that may induce an electromagneticfield; magnetic fields resulting from materials with encoded quantumspin effects; induction magnets, in which ferrous material exposed to aperpendicular, or substantially perpendicular, electromagnetic field maybe subject to a force pulling it towards the center of theelectromagnetic field; other suitable magnets; or combinations thereof.

In certain embodiments, magnet shapes that could be used but not limitedto are: cylinders; cuboids (suitable 3D shapes); segmented, where themagnet is made up of in whole or in part a cluster of smaller magnets;Trapezoidal; solid or hollow (e.g. toroidal shape or hollow cylinder);Groups, either of the substantial the same polarity or opposing; angularand/or radially offset repetition of above arrangements; other suitableshapes for a particular application; or combinations thereof. Thethickness of magnets may be either equal to or not be equal to thestator mount/platter thickness. The thickness of coils may be variableto suit the application. In certain embodiments, the number of magnetsand coils may or may not be set such that: the number of coils never isthe same as the number of magnets, to ensure one or more, asubstantially plurality or all the magnets and coils never completelyalign; if number of coils is equal to number of magnets, the magnet orcoil position is geometrically offset to substantially prevent, prevent,or reduce their concentric alignment or combinations thereof. In certainembodiments, the magnets and/or coils may be aligned such that: magnetsmay suitably axially aligned with coils or vice-versa, such as in anaxial flux configuration; magnets are suitably axially misaligned withcoils or vice-versa up to 20, 25, 30, 35, 40, 45, 50, 55, 60, or 65degrees; aligned, or substantially aligned, with the platter;substantially perpendicular, or perpendicular, to platter; othersuitable configurations perpendicular or combinations thereof.

Stator

Certain embodiments of the disclosed electrical machines may incorporateone or more stators which may be used to locate the electric coils. Thestator may be incorporated directly into the casing, independent or acombination thereof. As such the materials chosen for the stator followthe same convention outlined in the ‘Material’ section of the casingdescription or disclosed elsewhere herein. The chosen material may behighly (or suitably) conductive both electrically and/or thermally. Incertain embodiments, the one or more stators may be used as electricalconductor (power delivery), as heat sinks (from the electronics andcoils to casing), as well as mechanically supporting the coils andelectronics or combinations thereof. In certain embodiments, the one ormore stators may allow transmission of communication signals, eitherdigital or analog, superimposed on the power layer, on its own layer, orcombinations thereof. Thus, layers in the stator may be electricallyinsulated from each other, if they are used for electrical conductionpurposes. In certain embodiments, methods of insulation may include:hard anodisation; using insulating materials between layers such asplastics or combinations thereof. In certain embodiments, gaps may beincluded in the one or more stators to reduce material required and/orthe weight. When the stator is constructed out of conductive materialgaps may be added to eliminate eddy currents from forming around thecoil. For example as shown in FIG. 8 a gap 90 in the conductive stator91 is introduced in the stator near the location of the mounting holefor the magnetic coil 92 breaking the conduction path of the eddycurrent 93 induced when a current flows through the magnetic coil. Incertain embodiments, the gaps are located such that two concentricannular rings are not formed radially on either side of the ring formedby the coils.

Coils

Certain embodiments of the disclosed electrical machines may incorporatedifferent types and/or shapes of inductive coils, the purpose of whichis to by use of electric current, induce and/or alter an existingelectromagnetic field, creating a force which causes the rotor of themotor to turn. In certain embodiments, the coils may be constructed ofsufficient materials to handle both the heat and the electric currentrequirements of the motor; the coils may be constructed so as to lowerthe electrical resistance to ensure there is minimal power loss due toresistive heating; the coil may be constructed such that they produce amagnetic field sufficiently large enough to create sufficient force orcombinations thereof. One exemplary coil is shown in FIG. 4.

In certain embodiments, coils may be constructed as an air core, theconductive material is wrapped or rolled in such a way that there is anair gap in the middle of the coil; solid core, there is no (or suitablylittle) air gap in the middle of the coil. In certain embodiments, thecore may either be made of the conductive material used or be anon-conductive material, either ferrous or nonferrous. Ferrous materialswith a high magnetic permeability increase the magnitude of the magneticfield. In certain embodiments, the coil may be interleaved, the coil ismade from conductive ribbon and/or sheet. The ribbon is coiled from thecentre core to the outside while interleaving layers of insulatedferrous materials. The ferrous material acts as an insulator and as acore material to enhance magnetic field proportional to the number ofloops of the ribbon. The magnetic field may reach its maximum magnitudeat the centre of the coil with a sine distribution on either side.Combinations of the various constructions disclosed herein are alsocontemplated. The coils may be constructed in one or more of thefollowing shapes: round/cylindrical, square/cuboid, trapezoidal, solidor hollow (air gap)/annular, and other suitable shapes.

In certain embodiments, the electromagnetic coils may be wound, bentand/or otherwise constructed from one or more pieces of a conductingmaterial, or a sufficiently conducting material. The coils may be 3Dprinted or otherwise made. The conductor may be 3D printed along with acore (if 2 material (or more) 3D printing is used). The conductor may be3D printed and the core added in a separate process. 3D printing refersto selective laser sintering, selective electron beam melting and/orother selective deposition techniques.

In certain embodiments, coils may be affixed to the stator by: aglue/bonding agent, clamping, mechanically, welded, 3D printed directlywith the stator plate, or combinations thereof.

Coil and/or Magnet Positions

In certain embodiments, coils and/or magnets may be arranged/varied inmany different physical configurations. In certain embodiments, an axialflux configuration may be used comprising: at least one, two or multiplerotor platters of magnets creating an alternating magnetic fieldparallel, or substantially parallel, to the axel; and a plurality ofcoils between magnetic fields.

FIGS. 9, 10 and 11 exemplify a number of different configurations of theelectrical machine. FIG. 9 illustrates a cross section view of a rotorplatter configuration according to certain embodiments. The platter 8has a shaft 10 and a plurality of alternating pole orientation magnets94 and 95 (in this exemplary embodiment 18 magnets are present) andcoils 88 (in this exemplary embodiment 17 coils are present). Themagnets are arranged in a substantial concentric configurationarrangement near the outer edge of the platter. FIG. 10 is similar toFIG. 9, but has two rotor, element 8 which create a more concentratedmagnetic field across the coils, 88. Also shown is a spacer 12 betweenthe two platters. FIG. 11 is similar to FIG. 9 in a triple rotor platterconfiguration. This configuration permits more power to be added byadding appending extra coil platters.

FIG. 6 shows a top down view of the rotor platter 8 in theconfigurations illustrated in FIGS. 9 to 11. Shown are the 18alternating polarity magnets 9, distributed radially on the rotorplatter 8. Also shown is the location of the shaft 10.

Certain embodiments of the disclosed electrical machines may beconfigured in a substantially circular array (radially aligned) wherein:a plurality magnets and a plurality of coils may be axiallyperpendicular (or substantially perpendicular) to at least one rotorshaft's primary axis. In these embodiments, the magnetic properties of anormal axially aligned stator motor are present with the added benefitsof fine grained adaptive magnetic flux control. FIG. 12 shows aschematic top view of a rotor platter 97 wherein the magnets 94 and 95are axially perpendicular (or substantially perpendicular) to therotor's shaft 10 and are at least partially within the platter,according to certain embodiments. Also shown are a plurality of coils 5that are also axially perpendicular (or substantially perpendicular) tothe rotor's shaft 10 and are configured concentrically around the outerradius of the platter embodiments. The stator 98 can be seen holdingcoils 5 radially around the magnets. A clearance gap 96 can be seenbetween the magnets and the coils. FIG. 13 shows a perspective view ofthe configuration of FIG. 12. FIG. 14 is a photo of an electric motorbuilt with the exemplary configuration illustrated in FIGS. 12 and 13.

In certain embodiments, the configuration may be a linear sliderconfiguration. In this configuration coils and magnets are alignedlinearly alongside each other with alternating polarity, shown in FIG.15. Through the use of individual controllers for each coil, theadaptive magnetic flux array of certain embodiments has one or moreadvantages over a traditional linear motor or solenoid. By switching andholding certain coils, it is possible to lock the position of therotor/slider, 99, magnetically, without the need for a mechanicalmechanism which may wear. The configuration can be used to create linearmotion in both the forward and backwards direction 100, without the needof external control to switch the polarity of the main power supply tothe coils, if so desired. One use for the linear configuration is thatof power generation, the high efficiency in mechanical to electricalenergy conversion of the illustrated embodiment being advantageous togenerators operating over long periods of time with unstable input powerprofiles, such as tidal or wave power. As is the case for the rotationalmotor configuration, the linear configuration may also be stacked withother linear motors or generators, allowing the inside slider/rotor 99to be shared, whilst increasing power output of electrical powergeneration capacity. FIG. 17 shows a cross section of a linear motorconcept configuration, showing the position of the coils 5 in relationto the magnets 95. The direction of motion of the slider/rotor 99 inrelation to the stator mount 101 can be seen.

Besides linear, substantially linear, circular, substantially circular,arced, and/or substantially arced other configurations of the coils andmagnets may be constructed as long as at least one track of a pluralityof coils may be assembled wherein one or more array of a plurality ofmagnets suitable follow the coils. Some other configurations may becombination of linear, substantially linear, circular, substantiallycircular, arced and/or substantially arced.

Certain embodiments of the disclosed electrical machines may beconfigured in a substantially circular array (radially aligned) wherein:a plurality magnets and a plurality of coils may axially perpendicular(or substantially perpendicular) to at least one rotor shaft's primaryaxis. Such embodiments have the magnetic properties of a normal axiallyaligned stator motor, with the added benefits of fine grained adaptivemagnetic flux control.

End Caps

Magnetic fields that are not constrained may couple onto conductivesurfaces and induce eddy currents which may create magnetic fieldsopposing the motion of the magnets. For example, FIG. 18 is a sidecross-sectional magnetic field diagram of a linear array of evenlydistributed magnets, where consecutive magnets 95 have their north polefacing up, and the rest of the magnets 94 have their north pole facingdown, with electromagnetic coils in the middle inducing a magnetic fieldnorth 102 and south 103. FIG. 18 illustrates the external radiatingmagnetic field 104 without any shielding. FIG. 19 illustrates thereduction in radiated electromagnetic energy in the scenario describedin FIG. 18 with ferrous shielding plates 105 added. In certainembodiments, a Halbach array arrangement may be used instead of theferrous shielding. FIG. 20 illustrates the reduction in radiatedelectromagnetic energy in the application described in FIG. 18 with aHalbach array arrangement of magnets used on the top platter. TheHalbach array arrangement may use smaller magnets 106, and oppositepolarity magnets 107. The smaller magnet is positioned between the twolarger magnets with a magnetic field substantially perpendicular tothose of the bigger magnets. The smaller magnet bends the magnetic fieldlines from the first large magnet to the next large magnet and reducesthe distance to which the flux loops past the end of the plate 108. Thishas close to the same effect of adding a ferrous shield to the system,and may dramatically reduce the external electromagnetic energy; thishas the effect of saving the weight of the ferrous shielding plates thatwould otherwise be used in this application. Ferrous shielding 105 isused on the bottom layer of magnets for comparison.

Enclosure

The enclosures discussed herein serve numerous purposes. In certainembodiments, it may be designed to cover or enclose (partially,substantially or fully) the moving parts and circuit boards, it can alsohold one or more coils in place, the electronics in place, provides asource of heat sinking away from the coils and/or electronics, it cansupport the bearings and/or absorb axial forces on the shaft, it may beused as a conductor to shunt electrical power to and/or from theelectronics, or combinations thereof. The enclosure may be constructedfrom materials (or combinations of materials) which are sufficientlystrong to resist (or substantially resist) deformation due to loadsapplied from the rotor shaft. Additionally, in certain embodiments, itis desirable for the casing to sufficiently resist thermal fluctuationsresulting in part from the electronics current draw. Example materialsthat match these properties include, but are not limited to: aluminium,polymers or other suitable materials.

In certain embodiments, the enclosure may or may not be electricallyconductive. In certain embodiments, power and signal lines may routeplacements but the casing itself is not used as a conductor. In certainembodiments, the casing itself may be used as a conductor. In certainembodiments, portions of the enclosure may be electrically conductive,typically with conductive parts separated by insulating layers. Suchconfigurations allow power to be supplied directly (or indirectly) tothe electronics through the casing. In certain embodiments, conductivemount points may be attached directly (or indirectly) to the outsideand/or inside of the casing. In certain embodiments, portions of thecasing may be used as conductors for, for example, signal transmission.Nonconductive sections may be used to isolate conductive sections toallow multiple signal ‘lines’ through the casing. In certainembodiments, power configuration and/or electronic communication and/orother signals may be multiplexed onto the power lines at a higherfrequency by means of a suitable technology such as Direct SequenceSpread Spectrum (DSSS). The present disclosure also contemplatedcombinations the enclosure configurations discussed herein. In certainembodiments, one or more circuit boards may be replaced withconductive/tracks/pads routed and/or etched directly into the devicecasing. In certain embodiments, at least a substantial portion of thecircuit boards may be replaced with conductive/tracks/pads routed and/oretched directly into the device casing.

In certain embodiments, one of the purposes of the casing may be toextract heat from the electronics (for example, the coils). It is usefulif this heat is transferred to the environment surrounding the casing asefficiently as possible. In certain embodiments, methods of cooling thatmay be implemented include one or more of the following: active cooling(forced air flow); active cooling (force liquid flow); active cooling(refrigeration); passive cooling (heat pipe/pump transfer); passivecooling (convective heat fins, ribs); passive cooling (convectionholes); active or passive cooling (convection channels); chambered(sealed static fluid with high thermal conductivity to concentrateand/or direct heat flow); and entire enclosure sealed withnon-electrically conductive fluid.

In certain embodiments, circuit boards (and their attached electronics)may be mounted such that they do not move when subject to external orinternal forces (linear or angular accelerations of the motor) orvibrations. In certain embodiments, circuit boards (and their attachedelectronics) may be mounted such that they do not substantially movewhen subject to external and/or internal forces (linear or angularaccelerations of the motor) or vibrations. In certain embodiments,circuit boards (and their attached electronics) may be mounted such thatthey are sufficiently stable when subject to external and/or internalforces (linear or angular accelerations of the motor) or vibrations. Incertain embodiments, circuit boards (and their attached electronics) maybe mounted using one or more of the following methods: specificallyshaped cavities in the casing such that circuit boards can slot in witha transition or interference fit; modular inserts; circuit boardssandwiched between two casing components; mechanically fastened orclipped; glued, or otherwise permanently joined.

In certain embodiments, the switching circuitry may be attached (forexample by soldering) to a finned configuration of the casing. FIG. 2element 37 and FIG. 15 element 37 indicates these locations according tocertain embodiments.

FIG. 21 illustrates the configuration of switches and coils where theelectronic switches and drivers 111, 112 and coils 88 are integrated andmounted onto modular circuit boards. For applications that are not asmechanically constrained this represents a more flexible electrical andmechanical solution. FIG. 22 illustrates a certain embodiment utilizing17 coil driver unit with coil 114 illustrated in FIG. 21 mounted in acircular array, utilizing two Motor Control Units 113, directlycontrolling the coils via the Coil Drivers 111 circuit boards. Incertain embodiments, electronic components (and/or circuit boards) maybe attached to modular inserts that may be slot/snap/or be otherwiseattached to the primary casing externally, without the need todisassemble other inserts and/or the primary casing. In certainembodiments, electronic components (and/or circuit boards) may beconfigured as a modular insert that may be attached to the primarycasing externally, without the need to disassemble other inserts and/orthe primary casing.

In certain embodiments, the electrical machine may include at least oneelectrical bus and/or at least one optical bus. For example, whenmultiple microcontrollers are used, inter communication betweenmicroprocessors typically may occur over a bus. This bus may be mountedand constructed in one or more of the following ways: for electricalconductor (groove cut for circuit board, or other form of conductor tomount); for optical conductor (cut directly into casing, with reflectivecoatings applied to cut surfaces, and/or inserted into groove incasing); other suitable methods for mounting the conductor. In certainembodiments, when an optical bus is in use, optical transceivers on oneor more CCUs may be mounted to interface with the bus. Thus the CCUpositions may be tangentially arrayed around the optical bus.

In certain embodiments, another function of the casing may be to protectone or more internal components from external damage. It may bedesirable that the seams of the casing be waterproof. It may also bedesirable that the casing be covered in, and/or made partially of,vibration/impact absorbing coating (e.g. elastomer polymers). In certainapplications, the casing may be an optional mounting point for masterpower cutoff switch.

In certain embodiments, one or more power and/or control signals maypass through the enclosure. In certain embodiments, at least asubstantial portion of the power and/or control signals may pass throughthe enclosure. Mounts can be provided for these connections using one ormore of the following: lugs/clips, bolts, rings/sockets/clamps, weldpoints, and other suitable ways for mounting. Also for external controland/or information mounts one or more of the following may be used:switch mounts, calibration mounts (variable, quasi fixed controls), andembedded displays (LCD, or other). For Micro Bus Interfaces one or moreof the following may be used: galvanically isolated connections(optical, radio), USB, Serial, other digital and analogue connections,and other suitable ways or structures. In certain embodiments, formechanical outputs when applicable, the primary shaft may pass throughthe casing via one or more of the following ways: optionally, a bearingseal, variable diameters, unsealed pass through hole (exposed innerassembly) and other ways of sealing shaft passthrough point. In certainembodiments, the enclosure may also have mounting points for magneticcoupling platters.

Switch Architecture

In certain embodiments, one or more electronically controlled switchesmay be used to control the size and direction of the current through thecoils. These switches may be made up of discrete components (e.g.,transistors and/or other silicon switch technology) including one ormore of the following: IGBT's or other similar technology; FET's orother Channel/Field effect transistor based device (MOSFETS etc); BJT'sor other bi-polar transistor based device; ECP or other emitter coupledtransistor device; digital switches such as transistors; silicon carbidetransistors; diamond switches; Triacs; Diodes; SCRs; other suitableelectronically controlled switching technology; and electromechanicalrelays. In certain embodiments, the one or more switches may be used todrive the electromagnetic coils and may be implemented in different waysand may be comprised totally or partially from one or more of thefollowing configurations/devices: single switch; an H-bridge (fullbridge); a Half bridge; a Half bridge with a high and a low sideswitching; bilateral switch configurations, single phase voltage sourceinverter, half bridge voltage source inverter, AC chopper regulation andother various one two, three phase and multiphase configurations.

The switches may be obtained without their plastic packaging andembedded directly into the one or more coils. Switches may be integratedinto the body of the one or more coils, either after or during theconstruction process of the one or more coils. In certain embodimentsreferencing 23 where the high side switches 85 and 89, the transistorsmay be biased to the high side of the coils. When using Positive FieldEffect Transistor (PFET) or Positive Negative Positive (PNP) Bi JunctionTransistors (BJTs), a negative voltage is applied in reference to theirpositive input and the control pin may turn on the gates. PNP BJTs andPFETs are generally more expensive than Negative Positive Negative (NPN)BJTs, Negative FETs and IGBTs. These devices would turn on if thevoltage at their controlling terminal is greater than the voltage attheir negative terminal by a few volts. In certain embodiments, toachieve this one or more of the following may be used: a charge pump; anisolated DC-DC converter; a separate power supply; and other voltageboost methods may be used. It is possible to vary the current flowingthrough the coil by use of pulse width modulation. In certainembodiments, the switches may be turned on and off at a high frequency,and by controlling the duty cycle (the time the switch is on compared tothe time the switch is off) the amount of current flowing through thecoil is controlled by this duty cycle. If the switches are just on (100%duty cycle), then the maximum current flows through the coil. If theswitches are off (0% duty cycle), then no current will flow through thecoil. If the switches are on half the time and off half the time thecurrent could be 50% of the full current but may depend if theinductance of the coil at the switching frequency is too high or toolow. In certain embodiments, when the direction of current through thecoil does not need to be reversed, a single switch can be used betweenthe voltage source, the coil and the ground. This reduced the componentcount by three switches. In a single phase AC configuration the voltagecan be half rectified to create a positive rail and a negative rail. Thetwo rails can then be switched through the coil to ground effectivelychanging the direction of the current. This reduces the number ofswitches required by two. In certain three phase star configurations,the phase with the nearest ideal voltage may be switched so that powercan flow from that phase to ground. In certain delta three phaseconfigurations, two switches may be required on either end of the coilto each phase, in this configuration current can be selected to flowfrom one or more phases to one or more other phases.

Control

In certain embodiments, one or more control mechanics may be used withrespect to the driving operation of one or more electronic components.The one or more control mechanics may be implemented either at ahardware or software level, or both. In certain embodiments, the numberof coils activated at a particular instance may be varied from 0 to thetotal number of coils. The choice of this number may be based at leastin part upon the currently active control scheme. This decision may bemade at the Main Control Unit (MCU), Coil Control Unit (CCU) and/or anexternal level. In certain embodiments, motors may be configured tooperate in the clockwise, counter clockwise, or both directions. Incertain embodiments, in order to produce motion, coils may be switchedon and off at specific instants. These instances may be determined byone or more of the following:

A. stored sequences including: observed (obtained via sensor feedback);streamed (obtained via external devices); precomputed (stored within themotor electronics);

B. computed sequences including: sequential based activation (coils aretoggled sequentially in a rotary fashion with alternating polarity);Optimal force activation (coils are activated when their individualfeedback data indicates an optimal force will be applied to the rotor);optimal efficiency activation (coils are activated in a manner tomaintain target operating motor dynamics whilst minimizing powerconsumption); and random based activation (coils are activatedrandomly); pattern based sequence (coils are sequenced in apredetermined pattern); feedback frequency based (Coils are activatedbased on a driving analogue frequency signal); and

C. Other suitable driving sequence which achieves desirable motorperformance.

In certain embodiments, feedback may be used to generate and/or chooseoptimal driver routines/patterns to adapt the device to changingconditions such as but not limited to: changing temperature or othertemporary forces/stress' that may alter motor operational performance; adepleted battery/changing voltage supply; an increase in demand on agenerator or for mechanical output in an application; change inparameters of the device caused by damage and/or general wear and tear;or combinations thereof.

In certain embodiments, certain electrical machine parameters may becalibrated using sensor feedback or other ways of tuning. For example,the use of machine learning techniques, and/or other automated tuning,operating internally, externally or combinations thereof may be used.

In certain embodiments, the active control scheme can utilize severaltechniques to reduce power consumption and/or better optimize powerconsumptions. For example, one or more of the following may be used:dynamic reduction of active coil count (lower power per torque); dynamicreduction of active coil power percentage (smoother torque); back EMFreproduction/elimination optimization; and pulse width modulation of thecoil driving signal to allow precision control on power applied tocoils.

In certain embodiments, feedback monitoring may be used to detect faultsand automatically power off faulting devices. For example, one or moreof the following: coil current overflow protection/detection;over-voltage/Over power protection; overheating protection; and velocityoverspin protection. In certain embodiments, arbitrated mastermechanisms may be used such as master controllers may be nonsingular,with the resulting control signal arbitrated using a 3 way votingmechanism to ensure redundancy of the master controller. In certainembodiments, an external signal may be applied to bypass one or moresingle controllers with the purpose of shutting down, restarting, orreconfiguring the one or more controllers.

Feedback

In certain embodiments, feedback may be useful for optimal operationunder one or more conditions, but may be only cost effective forincorporation into certain devices. When feedback is not required, astandard open loop control may be used. Feedback may be utilized by thecontrollers, either by CCUs or MCUs or both. In certain embodiments,feedback may be collected local to each device or remotely and used ineither hardware and/or software as outlined in the control sections. Incertain embodiments, feedback may be collected local to one or moredevices or remotely and used in either hardware and/or software asdiscussed herein. In certain embodiments, feedback may be measuredand/or obtained in one or more of the following ways: instantaneousvoltage across a coil via a ADC, or otherwise, at any time orsubstantially any time; current through a coil or power supply, byeither contactless (hall effect) or contact current measurement; backEMF measurement, may be done while coil is not in a powered state;angular position, obtained by a sensor as discussed herein; magneticfield strength or angle; temperature; and vibrations via accelerometersor otherwise. In certain embodiments, angular positions of the rotor maybe obtained by measuring one or more of the following: absolute angle orposition; relative angle or position; and velocity. In certainembodiments, readings may be achieved through the use of sensors such asone or more of the following: Hall effect and/or other magnetic sensetechnology, such as GMR, AMR; rotary and/or quadrature encoder, opticalor otherwise; position/velocity detection sensors such as laser/opticaltrackers currently used in computer mice; and cameras in combinationwith software processing.Controller ArchitectureIn certain embodiments, axial flux electrical machines may comprise:coil driving controllers, coil control units (CCU's) and/or motorcontrol units (MCU's). In certain embodiments, the layout of thecontrollers may be varied, while maintaining control of each coilindividually.). In certain embodiments, the layout of the controllersmay be varied, while maintaining control of one or more coilsindividually. In certain embodiments, the layout of the controllers maybe varied, while maintaining control of at least a substantial number ofthe coils individually. In certain embodiments, the layout of thecontrollers may be varied, while maintaining control of at least 50%,60%, 70%, 80%, 90%, 95%, 98%, 99% or 100% individually. The controllersdrive ‘switches’ as described in this disclosure, allowing control ofthe coils, as described in this disclosure. FIG. 24 illustrates oneexemplary relationship between an exemplary Motor Control Unit (MCU)113, Coil Control Unit (CCU) 115 the communications buses 116, 117 thatare available to them. One or more MCU's may be communicating with oneof more CCU's. Also illustrated is the coil driver architecture,according to certain embodiments, which includes a one or more coildrivers 111 for one or more coils 88. The signalling between CCU's,MCU's and coil drivers may be galvanically isolated. FIG. 25 illustratesa CCU architecture 115, according to certain embodiments.A Microcontroller 118 may be used to control the device; it incorporatesan Analogue to digital converters (ADC) 122 for collecting data fromsensors 121. A Communications transceiver 119 is connected to themicrocontrollers serial bus 120 allowing it to receive commands andexchange data with a MCU. The microcontroller controls a coil driver 111by use of a digital bus or PWM. The coil driver takes a high voltageinput 123 and controls the supply of that to the coil 88. Themicrocontroller and other peripheral low power devices may be supplied ahigh efficiency DC to DC converter 124. Galvanic isolation is optionalat several points 81. In certain embodiments, the number of controllersused may be varied depending on specific needs of the application. FIG.26 shows a 1:1:1 configuration such that one individual Motor ControlUnit (MCU) 113 communicates with one Coil Control Units (CCU) 115, whichin turn controls for each switch and or switch driver 114 in a 1:1:1configuration. (for example as shown in FIG. 26); many switchescontrolled by one or more CCU's, in a 1:n (for example as shown in FIG.27) or m:n configuration (for example as shown in FIGS. 28 and 29);motor Control Unit (MCU) may control CCU's, giving velocity and/or othercommands; and MCU's may directly control one or more coils, bypassingthe need for CCU's.

In certain embodiments, the controllers may be implemented throughmultiple ways, examples include one or more of the following:utilization of software and/or hardware features in an embedded systemsuch as a microcontroller or microprocessor; the use of an FPGA, CPLD,ASIC or other VLSI or programmable logic device; an analog system, suchas the use of classical electrical feedback topologies to create basiccontrol loops; and combinations thereof.

FIG. 30 illustrates a certain embodiment, in which there is multiplemicroprocessor configurations, the master controlling processor may be,for example, a CCU 115. In certain embodiments, CCU's may actindependently, without the need for a master controller. In certainembodiments, CCU's may act independently, without the need for a mastercontroller wherein synchronous behavior may be achieved through the useof common sensors, or sensors with predictable and consistent readingsrelated to the electrical machines behavior. In certain embodiments,where the motors speed and/or power is uniform (or substantiallyuniform), and the only input to the system is that the power is on oroff, a common communication bus may not be required.

Certain embodiments are directed to an MCU's (Motor control unit) in astandard master slave configuration where a single motor control unit isconnected to a common communication bus, which is connected to one ormore coil control units. Certain embodiments are directed to an MCU's(Motor control unit) in a standard master slave configuration where asingle motor control unit is connected to a common communication bus,which is connected to at least 70%, 80%, 90%, 95%, 98%, 99% or 100% ofthe coil control units. FIG. 31 shows a configuration where a singlemotor control unit (MCU) 113 is connected to a common communication bus125, which is connected to each of the coil control units (CCU) 115.Certain embodiments are directed to redundant master slave configurationwhere multiple masters arbitrate to come to an accepted value. Forexample 2, 3, 4, 5, 6, 7, 8, 9, or 10 MCU's may calculate commands tothe CCU's, but only one MCU's commands are used by means of anarbitration method. In this way in the event of failure the failed MCUwill be ‘outvoted’ and their commands discarded, possibly even beingpowered off by the other MCU's. Other embodiments may include redundantMCU's in case of failure, which only actively send commands when anotherMCU has failed. FIG. 32 shows a configuration where 3 motor controlunits (MCU) 115 are connected to a common communication bus 125, whichis connected to each of the coil control units (CCU) 113. In certainembodiments, it is possible to have configurations wherein one or moreof the coil control units are not in communication with the plurality ofmotor control units. In certain embodiment, one or more of the CCU's mayact together as a group, sharing sensor data and/or providing commonoutput. In such embodiments, communication may occur via a common bus ordirect peer to peer. In such embodiments, a motor control unit may notbe required. FIG. 33 illustrates a configuration wherein no centralcommunication bus is present and communication from each CCU 113 ispoint to point 126. FIG. 34 illustrates a configuration wherein acentral communication bus (token ring) 127 is used for communicationbetween CCUs 113. In both FIGS. 33 and 34 a MCU is not required.

In certain embodiments, power systems for supplying the digital logicand/or other devices in the CCU's and/or the MCU's may need to convert ahigher or lower voltage to the operating voltage of the devices used,and can take one or more of the following the topologies: DC-DCconverters, switching such as buck or boost; linear regulation orotherwise; transformers; resistive supply (by division); and opticalpower transfer. In certain embodiments, power may be supplied to thecontrol units, CCU's, MCU's, an overall motor and/or another device.Such implementations may include one or more of the following: using thesame (or substantially the same) supply the switches use, such as whenswitches are mounted to a motor casing; from RF/EM ‘waste’ or‘background’ energy harvesting; via EM induction/generation, such as inthe application of a generator; batteries, either per CCU/MCU deviceand/or otherwise, rechargeable or non-rechargeable; solar, wind, hydroand/or other forms of renewable energy sources; and mains supply, singlephase, three phase at a variety of different voltages.

In certain embodiments, power supplies for switches and/or CCU's/MMU'smay also have power control overrides, as a safety feature, allowingpower to be turned off to one or more CCUs or coils. This can beimplemented via suitable switching topology, for example, as discussedherein.

In certain embodiments, communications between a MMU and an externalcontroller, MMU and internal CCU and/or other devices may begalvanically isolated by using one or more of the following methods:optical (IR or other spectrums) over a physical medium as a light guidelike fiber or shaped plastic, through space/air or otherwise; radioFrequency of suitable spectrums, physical layer technology, and/orencoding method, such as Direct Sequence Spread Spectrum (DSSS), O-QPSKor otherwise; conductive, via wires and/or other electrically conductivematerial, and isolated via the use of a galvanically isolatingtechnology such as: RF isolation IC's, transformers, capacitive, opticalisolation IC's, or combinations thereof.

FIG. 35 illustrates a configuration with two redundant communicationbuses 128. In certain embodiments, the communication layers may have 2,3, 4, 5, 6, 7, 8, 9, 10 or more redundant layers.

In certain embodiments, communications inside the devices betweencontrollers/drivers/MCU's 115 and/or CCU's 113 and/or to externaldevices, (e.g. vehicle control unit to MCU) may involve one or more ofthe following technologies and/or communications protocols incombination with one or more of the physical layer implementationsdisclosed herein: single ended, serial and/or parallel (for exampleUART, SPI, or I2C), differential signalling, (for example CAN bus orRS485 protocols), optical point to point and/or optical bus and RFcommunications.

With reference to FIG. 1, a brushless, axial flux, direct-currentelectric motor 1 comprises one or more disc-shaped stators, each (or oneor more) of the stators comprising first annular conductive element 4and second annular conductive element 2, the conductive elements may beseparated by an electrically insulating layer 3. In certain embodiments,the insulating layer may be made from a mechanically tough materialhaving a high dielectric value, such as Kapton. Other suitable materialsmay also be used. In certain embodiments, (not shown) the stators may beelectrically separated by hard anodising of their surfaces with caretaken to ensure that the anodising extends substantially, orsufficiently, to their edges, the anodising being employed alternativelyand/or in addition to the insulating layer. Around the periphery of thestators is embedded a circular array of equally-spaced, or substantiallyequally-spaced, electromagnetic coils 5, heat from the coils may beconducted out to the exterior surface of the annular conductiveelements. In certain embodiments, the elements may be made from a lightmaterial of suitable mechanical strength and/or conductivity, such as analuminium or magnesium alloy, and the external surfaces may be finned orribbed to provide greater heat dissipation surface area. Other suitableheat dissipation mechanisms or methods may be used. Annular conductiveelements 4 may be made with radially inward projecting fingers (depictedas 37 in FIG. 3) employed as power conductors (described further herein)and the omission of the fingers from annular conductive element 2creates an internal space in which is accommodated one or more stackedcircuit boards 6. These stacked circuit boards 6 may be parallel,substantially parallel and/or other suitable configurations. In certainembodiments, (not shown), the circuit boards may be partially, orwholly, replaced by a system of internal conductors. In certainembodiments, the circuit boards may be supported by the solder tags ofsolid-state switches 7 being soldered to them, the switches, in turn,being fixed (as described elsewhere herein) to the fingers of annularconductive elements 4. In certain embodiments, (not shown) the circuitboards are supported from the stators by a suitable structure, includingconductive brackets, insulating brackets, pillars, struts orcombinations thereof. The electric motor may further comprise one ormore disc-shaped rotors 8 around the periphery of which may be embeddedin a circular array of equally-spaced (or substantially equally-spaced),powerful permanent magnets 9, the array may have the same, orsubstantially the same, centre diameter as that of the electromagneticcoils and the magnets may have alternating pole orientation. In certainembodiments, (not shown), the centre diameters of the arrays ofpermanent magnets and electromagnetic coils may be made unequal but suchthat the magnetic fields of the magnets and coils intersect. In certainembodiments (not shown), the poles of the permanent magnets in the arraymay have like orientation. In certain embodiments, (not shown), thepermanent magnets in the array may be made in groups, the polarorientation of the magnets being common in each group while the polarorientation of adjacent groups may be opposed. In certain embodiments,(not shown), the permanent magnets in the array may be made in groups,the polar orientation of the magnets being common in one or more of thegroups while the polar orientation of adjacent groups may be opposed. Incertain embodiments, (not shown), the permanent magnets may be arrangedin groups of unequal numbers, the polar orientation of the magnets in agroup being common. In certain embodiments, (not shown), the permanentmagnets pass through the whole of the axial depth of the rotors and maybe orientated parallel, or substantially parallel, to the shaft, butwith their centre distances randomly displaced (displaced inwardly oroutwardly in a radial sense) up to half their radial depth. In certainembodiments, the displaced (displaced inwardly or outwardly in a radialsense) may be up to 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 oftheir radial depth. In certain embodiments, (not shown), the permanentmagnets in an array pass through the whole of the axial depth of therotor and may be displaced in common from being parallel (orsubstantially parallel) with the shaft by a deflection in various sensesof between zero and 30 degrees. In certain embodiments, the deflectionin various senses of may be between zero and 30 degrees, zero to 20degrees, zero to 40 degrees, 5 to 40 degrees, 5 to 30 degrees, 5 to 10degrees, 10 to 30 degrees, 20 to 35 degrees or other suitable ranges. Incertain embodiments, (not shown), the permanent magnets in an array passonly partly through the axial depth of a rotor, their inner endsoptionally abutting a back iron of suitable magnetically permeablematerial embedded in the rotor. In certain embodiments, (not shown), thepermanent magnets and the electromagnetic coils may be arranged inpossible combination of the embodiments disclosed herein. The rotors aresplined or otherwise fixed to shaft 10 parallel (or substantiallyparallel) to the stators with an air gap between the electromagneticcoils and the permanent magnets, suitable spacers 11, 12, 13, 14 beingpositioned on the shaft to maintain (or partially maintain) the rotorsin correct (or suitable) axial separation. The inner end of the shaft isrotationally supported in suitable bearing 16 carried in end plate 15 ofthe casing of the electric motor. The casing may comprise: end plate 15,annular conductive elements 4, annular conductive elements 2 and casingelements 17, 18, 19, 20, retained in a stacked arrangement by aplurality of assembly bolts 21 passing axially through them. Theexternal surfaces of the stacked elements may be finned and/or ribbed toprovide greater heat dissipation surface area and a suitable sealant (orsealing means) may be provided between abutting faces. Fixed to theouter end of the shaft is wheel flange 23 secured to the shaft byretaining nut 25. A plurality of wheel retaining bolts 24 is provided onthe wheel flange. The outer end of the casing is sealingly closed bythrust bearing housing 22 which accommodates suitable thrust bearing anda suitable sealant (or sealing means) (not shown) which rotationallysupport the shaft, support wheel loads, retain the wheel flange and theshaft axially and prevent, substantially prevent or sufficiently preventthe egress of lubricant or the ingress of contaminants. To provide aflux return path, annular back irons 26 of a suitable magneticallypermeable material may be provided on one or more faces (or each face)of a the rotor not facing a the stator, the back irons covering theannular zone occupied by the magnets. In alternative embodiments (notshown) in the rotors having a face not immediately adjacent the stator,the back irons may be deleted and the magnets take the form of suitableHalbach arrays. Electronics housing 27 is formed on or fixed to asuitably located part of the housing and contains control circuit board33. The solid-state switches are activated by command signals from acontrol system (not shown) to power the electromagnetic coils andthereby cause the rotors to rotate. Suitable sensors (not shown) areprovided to generate signals that are transmitted to the control systemto provide data as to the absolute and instantaneous positions of therotors. In certain embodiments, one or more suitable sensors (not shown)may be provided to generate signals that may be transmitted to thecontrol system to provide data as to the absolute, substantiallyabsolute, or sufficiently absolute and/or instantaneous, substantiallyinstantaneous, suitably instantaneous, relative, or substantiallyrelative positions of one or more of the rotors, or any combinationthereof. In certain embodiments, the sensors take the form of one ormore optical sensors and/or one or more Hall-effect sensors. In certainembodiments, (not shown), rotor position may be determined by referenceto the back EMF generated in undriven coils. In certain embodiments, thepermanent magnets may take the form of powerful, or sufficientlypowerful, rare earth-type magnets and may be secure in position withinthe axial depth of the rotors by, for example, bonding, by suitablemechanical fastenings or, as depicted in the figure in the central therotor, by imprisonment between two parts clamped together. In certainembodiments, (not shown) which may be employed in lower costapplications and/or those required to meet different operationalparameters, the magnets take a conventional form. The body parts of therotors are made sufficiently strong and/or rigid to suitably resistmagnetic forces generated during operation and/or when the rotors are atrest. The rotor body parts are optionally made solid and/or partiallyhollow with radial ribbing to reduce rotating mass and/or conferstiffness. In certain embodiments, the electromagnetic coils may be madein the form described in relation to FIG. 4 and generate suitably highermagnetic flux levels while having suitably lower magnetic reluctancepermitting rapid switching and/or reversal of magnetic polarity. Incertain embodiments, (not shown), coils of conventional, wire-wound orribbon-wound, bobbin construction may be employed, with an air coreand/or core made from a suitable magnetically permeable material. Incertain aspects, the coil configuration may necessarily be a compromisebetween maximisation of current flow and minimisation of inductanceeffects and/or losses due to at least in part hysteresis. Electricalcurrent may be supplied to the solid-state switches via the annularconductive elements 4, thereby permitting a heavy current flow to thesolid-state switches. A plurality of suitable lugs (depicted as 34, 35in FIG. 3) may be provided around the peripheries of the annularconductive elements for the attachment of electrical conductors. Theelectromagnetic coils may be embedded within the axial depth of thestators and may be bonded into place and/or potted with, for example, ahigh-strength, high-temperature epoxy resin, the arrangement permittingefficient (or suitably efficient) conductive cooling. The stators may bemade sufficiently strong and/or rigid to resist magnetic forcesgenerated during operation and/or when the rotors are at rest. Incertain applications, where the electric motor may be employed as adirect-drive automotive wheel motor, it may be mounted to the suspensionof a vehicle by suitable fastenings engaging attachment bolt apertures28 provided in casing end plate 15.

In certain applications, where the electric motor may be employed as adirect-drive automotive wheel motor, the centre diameters of the arraysof permanent magnets and arrays of electromagnetic coils fall in therange 15 to 60 centimeters, the number of the coils being odd and thenumber of the magnets being one more than the number of coils. Othersuitable ranges may also be used. In certain embodiments, 18 the magnetsmay be employed. In certain other embodiments employing similaroperating principles, the numbers of the permanent magnets and theelectromagnetic coils may optionally be doubled, tripled or quadrupledand the coils powered as required to generate a desired torque and RPM.In certain applications, the number of the permanent magnets and thenumber of electromagnetic coils may 1, 2, 3, 4, 5, 6, 8, 10, 12, 14, 20,or more and the coils powered as required to generate a desired torqueand RPM. Similarly, in other alternative embodiments, the permanentmagnets and the electromagnetic coils may optionally be made in equalnumbers. Similarly, in other alternative embodiments, the permanentmagnets and the electromagnetic coils may optionally be made in equalnumbers, but with locational asymmetry to prevent magnetic stasis atstart-up. In certain applications, the greater centre diameter of thearrays of permanent magnets and electromagnetic coils, the greater thetorque able to be generated. The arrangement of the electric motorpermits many combinations to be created from specially designedcomponents, standard components, or combinations thereof—from a singlerotor and stator combination to combinations employing at least 10rotors. In certain applications the number of rotors may be at least 5,10, 15, 20, or 25. The combinations employing larger numbers of rotorsand stators may be used in large devices or machines, such as heavytrucks and earthmoving equipment.

In certain embodiments, the solid state switches employed to provideelectronic commutation may be insulated-gate bipolar transistors (IGBT)which may be capable of handling the supply voltages required by theelectric motor. Although both p-type (P-FET) and n-type (N-FET)field-effect transistors may be suitable for the application, in thecertain embodiments, IGBTs may be employed in an H-bridge arrangementwith powering of the high side of each (or one or more) of the IGBT byan integrated circuit incorporating a charge pump. In the certainembodiments, IGBTs may be employed in an H-bridge arrangement withpowering of the high side of one or more of the IGBT by, for example, anintegrated circuit incorporating a charge pump. The positioning of theIGBTs immediately adjacent the electromagnetic coils may provide short,efficient conduction paths of low resistance. Other positioning may alsobe used such as substantially adjacent, suitably adjacent or incommunication with. The type of the IGBTs employed may provide largetabs intended as heat sinks, but which may be also electricallyconductive. The tabs may be therefore fixed directly, or indirectly, tothe fingers of annular conductive elements 4, thereby providing theIGBTs with an efficient electrical current supply path with lowresistance, making efficient use of space and/or providing an efficientthermal conduction path out to the finned or ribbed exterior surfaces ofthe annular conductive elements.

With additional reference to FIGS. 2 and 3, a plurality of suitable lugs34, 35 may be provided around the peripheries of the annular conductiveelements for the attachment of electrical conductors, connectors 29, 30being provided on each the lug. To prevent (substantially prevent,sufficiently prevent or reduce) the generation of an electrical eddycurrent around one of more of the electromagnetic coils, slots 38extending more or less radially inwards from each aperture accommodatinga the electromagnetic coil may be created by cutting away, for example,alternate finger 37. The IGBTs may be partially accommodated in slots 38and first connections (depicted as 42 in FIG. 4) to the windings of theelectromagnetic coils pass to common ground plate 39 via one side theslots, suitable insulation being provided to electrically isolate theconnections from the surfaces of the slots. Second connections (depictedas 41 in FIG. 4) to the windings of the electromagnetic coils pass tothe IGBTs via the other side of the slots. Connections of the IGBTs tothe common ground plate may be made at 40. DC to DC isolated converters44, 46 and high voltage step-down regulator circuit boards 43, 45 may bemounted to the inner edge of circuit boards 6. Two independent powersupplies may be employed to prevent, or substantially prevent, theexistence of a closed conductive loop, thereby preventing (substantiallypreventing or sufficiently preventing) induced current from adverselyaffecting electronic functions. Similarly, to prevent, substantiallyprevent, or sufficiently prevent induced current from interfering withcommand and feedback signals, inner and/or outer circuits may begalvanically isolated. In some embodiments, the galvanic isolation isachieved through the use of infra-red transmitting circuit 47 andreceiving circuit 48, with one such pair provided for each the stator.In the certain embodiments, control signals from microcontrollers on theinsides of the stators (depicted as 81 in FIG. 7) may be galvanicallyisolated using electromagnetic (RF) isolation structures or techniques.In alternative embodiments (not shown), the galvanic isolation may beachieved through the use of optical, capacitance, induction,electromagnetic, acoustic, mechanical structures or techniques orcombinations thereof adapted for the purpose.

With additional reference to FIG. 4, in the certain embodiments, acurrent of 90 Amperes at 120 Volts may be required to be supplied to theelectromagnetic coils to achieve maximum power output from the electricmotor. In the certain embodiments, electromagnetic coils 5 may be woundup from two separate strips of copper foil 49-52, etc and 53-56, etcaround a suitable magnetically permeable core 61 of squarecross-sectional shape. The turn of the copper foil windings may binterleaved with rectangles of grain-oriented silicon steel 57-60, etcspecially cut to shape. The steel is often supplied coated with aninsulating compound but, when cut, uninsulated edges are exposed to thecopper foil windings. In practice, in certain applications, this hasonly a minimal effect upon coil function as, because of the lowerresistance of the copper foil, the proportion of total current passingthrough the steel plates is also minimal. The inner ends of the copperfoil windings are connected to insulated conductors 41 which are led outvia the gap between the two the copper foil windings and via suitablylocated apertures in the appropriate the steel plates and, together withthe outer ends 42 of the copper foil windings, are extended as requiredto make the necessary connections between the coils and the IGBTs. Theelectromagnetic coils may be bonded into place in the stators with, andpotted with, for example, a high strength, and high temperature epoxyresin adhesive. The electromagnetic coils may be wound with copper foilto reduce inductance effects and, thereby, to increase the maximum rateof polarity switching. In certain embodiments, a maximum switching rateof 400 Hz being achieved. In certain embodiments, a maximum switchingrate of 100 Hz, 200 Hz, 400 Hz, 500 HZ, 600 Hz or 800 Hz may beachieved. In certain embodiments (not shown) to meet differentoperational parameters, higher or lower switching rates may be achieved.By also reducing back EMF, the voltage required to operate the electricmotor at a given speed may be reduced. In certain embodiments (notshown), the electromagnetic coils may be made by computer-controlleddeposition of copper and a suitable ferromagnetic material to create afacsimile of these embodiments of the coils, the built-up assembly thenbeing given permanent form by sintering. In certain embodiments (notshown) the copper foil part of the electromagnetic coils may be made bycomputer-controlled deposition and electron beam welding or sintering,following which, pre-cut pieces of the grain-oriented silicon steel maybe slid into the apertures between the turns of copper foil. Forexample, copper foil having a thickness of 0.2 millimeters and a maximumeffective width of 25 millimeters is able to carry the desired maximumcurrent of 90 Amperes. Other suitable foil configurations may also beused. With a thickness of 0.23 millimeters, the volume of thegrain-oriented silicon steel within the electromagnetic coil issufficient to allow generation of the necessary magnetic flux strength.The thicknesses of the copper foil and the grain-oriented silicon steelmay be intended as substantially only indicative and, in alternativeembodiments, thicker or thinner materials are optionally employed. Incertain embodiments (not shown), electromagnetic coils of conventional,wire-wound or ribbon-wound, bobbin construction may be employed, with anair core or core made from a suitable magnetically permeable material.In another alternative embodiment, the electromagnetic coils may be madewith high-temperature superconducting windings. The coils may be madewith an air core and/or liquid nitrogen cooling techniques or means maybe employed to maintain a suitable operating temperature.

With additional reference to FIG. 6, in certain embodiments, powerful(or sufficiently powerful) permanent magnets 9 of circularcross-sectional shape may be embedded in the thickness of rotor disc 8as described herein. Suitable slots 63 may be provided in the rotor discto reduce the rotating mass and thereby the angular momentum of therotors and to permit an axial flow of air within the electric motorcasing. The centre bore 64 of the rotor disc is splined to accommodatecomplementary splining of the shaft. With additional reference to FIG.5, in certain embodiments, powerful permanent magnets 9 may be made moreor less trapezoidal in shape and abutting each other with alternatingpole orientation. In certain implementations, one or more of the magnetsmay be abutting. In certain applications, the magnets may be made moreor less trapezoidal in shape and abutting, substantially abutting, eachother with alternating pole orientation. In these embodiments, theradially inner edges of the permanent magnets may be shaped to engage(or communicate with) a complementary shape formed in the outer edge ofthe rotor disc, the side edges of the magnets may be shaped to engage(or communicate with) complementary shaping of adjacent the magnets inan array and the magnets may be retained in place on the rotor disc by acircumferential restraining band (not shown) of a high-strength metalmaterial. The central bore 62 of the rotor disc is splined toaccommodate complementary splining of the shaft. In certain embodiments(not shown), the powerful permanent magnets may be shaped approximatelytrapezoidal, but with the axis of one or more inclined to a radialpassing through it by an angle of between 2.5 and 20 degrees. Otherranges of angles may also be used, for example, an angle of between 2.5to 5 degrees, 5 to 25 degrees, 5 to 10 degrees, or 15 to 20 degrees.

In certain embodiments (not shown), individual small circuit boardscontaining power electronics, including the H-bridge, microcontrollerand galvanic isolation means may be placed on the stator disc adjacentone or more of the electromagnetic coils. The circuit boards arepositioned radially outside of the coils, but occupy minimal space anddo not substantially inhibit conductive cooling of the coils. Thereduced conductor length between the power electronics and the powerinput reduces losses due to resistive heating. A ring of clear polymermaterial serves as a light tube to relay control signals to themicrocontrollers. In certain embodiments (not shown), the IGBTs may bemade integrally with the copper of the electromagnetic coils.

With reference to FIG. 7, reflective optical position sensor 65 andHall-effect sensor 66 provide rotor position-related signals tomicroprocessor-based control unit 67. The control unit optionally takesthe form of a microcontroller and/or programmable logic device and/orprogrammable gate array and/or other custom-built unit. From theinterior 70 of the electric motor, the control unit transmits data viagalvanic isolation transmitter 68 to galvanic isolation receiver 72 onthe exterior 71 of the electric motor and thence to microcontroller unit75. Similarly, microcontroller unit 75 transmits data to control unit 67via galvanic isolation transmitter 73 and galvanic isolation receiver69. Separate bi-directional galvanic isolation means may be required foreach the stator. From microcontroller unit 75, data is transmitted toand from a master control unit via conductors 74. Microcontroller unit75 optionally takes the form of a microcontroller and/or programmablelogic device and/or other purpose-built logic device. Control unit 67communicates with switch drivers 80, 82 via galvanic isolation unit 81.The galvanic isolation units optionally employ one or more of theoperating principles described herein and one the galvanic isolationunit is provided for one or more of the stators. Electrical current issupplied to H-bridge arrangement of IGBTs via conductors 83, 84 andIGBTs 85, 86, 87, 89 are controlled by the switch drivers.Electromagnetic coil 88 is connected to the H-bridge such that currentflow reversal via switching reverses the magnetic polarity of the coil.Electrical current is supplied to DC to DC down-converter 77 viaconductors 76 and the down-converter supplies current to isolated DC toDC down-converter (switching) 78 and isolated DC to DC down-converter(logic) 79. The down-converter (switching) supplies electrical currentto galvanic isolation unit 81, the switch drivers and the IGBTs and thedown-converter (logic) supplies electrical current to control unit 67.

Control unit 67 permits arbitrary switching of one or more of theelectromagnetic coil independently of the other the coils. Usingpulse-width modulation, excitation waveforms can be generated and usedto drive the coil. A wide variety of coil drive profiles can be employedfor the real-time maximisation of efficiency and power output over awide range of RPM and operating temperatures. In certain embodiments ofthe operating method of the electric motor, maximum power may bemaintained by simultaneously powering the electromagnetic coils exceptone, the magnetic polarity of the powered coils being alternating. Theun-powered coil is then re-powered with opposite magnetic polarity suchthat it opposes the magnetic polarity of the preceding the coil(proceeding in the sense of the direction of rotation of the rotors)while the next coil (next in the same rotational sense) is de-powered.The process is continued with each successive coil being de-powered andthen re-powered with opposite polarity to complete a movement of the oneor more permanent magnets from one the coil to the next. Thus, for acomplete rotation of the rotors, the number of the coil de-powerings andre-powerings (with opposite polarity) in the coil array is given by thesquare of the total number of the coils in the array. Where the numberof powered the coils in an array is n, the electric motor is therebyelectromechanically geared, in effect, by a ratio of n:1. In certainembodiments of the operating method of the electric motor, minimum poweris maintained by powering one or more of the electromagnetic coils onlyonce per rotation of the rotor such that each the coil attracts only onethe magnet in the peripheral array of magnets. The electric motor isthereby electromechanically geared, in effect, by a ratio of 1:1.Various sequences or combinations of the coil powerings and de-poweringsmay be employed to achieve a nominated electromechanical gearing.

In certain embodiments (not shown), to reduce cogging effects and/or tomaximise efficiency, the back EMF of an unpowered the electromagneticcoil is recorded at a representative range of speeds using theanalogue-to-digital converter in the microcontroller. During operation,the electromagnetic coils in an array that are normally un-powered maybe powered to a level at which the magnetic flux generated equals, orsubstantially equals, the back EMF effect of the coil, therebyneutralizing the magnetic interaction between the un-powered coils andthe permanent magnets. The mechanism is also used in regenerativebraking permitting the wave to be analysed and then switched into thecorrect power planes. The characteristics of the back EMF of the coilsmay be further analysed during run time for a specific velocity, powerrequirement and operating temperature, and an optimal or near optimalwave generated using pulse-width modulation to, as far as is possible,maximise the efficiency of the electric motor. In the certainembodiments, such analysis may be performed automatically, substantiallyautomatically, on a continuous basis, on a discontinuous basis or othersuitable intervals. Pre-computed or partially pre-computed waveformpatterns may be stored in a look-up table and may be recalled whenspecific velocity, power requirement, operating temperature and,optionally, back EMF, or combinations of these, is detected. The look-uptables are optionally optimised through the use of meta-heuristicalgorithms, evolutionary algorithms, traditional, deterministicalgorithms, other suitable optimisation techniques or combinationsthereof. In certain embodiments, adaptive control may be implemented byperforming optimisation at run time through the use of an incorporatedsupport vector machine, through the use of neural network technology,through the use of fuzzy logic technology, through the use of othersuitable application of machine learning technology, through the use ofsuitable adaptive control techniques or through combinations thereof.

In certain embodiments (not shown), a supply of clean cooling air may besupplied to the interior of the motor casing as required to maintain thestators at a predetermined temperature. The cooling air may be exhaustedvia a suitable valve which maintains a predetermined minimum pressurewithin the casing to prevent, or substantially reduce, ingress ofcontaminants. The supply of cooling air is optionally cooled in arefrigerated heat exchanger before being supplied to the electric motorcasing. In another certain embodiments (not shown), a flow of liquefiedrefrigerant may be supplied to galleries formed in the casing wallsand/or stators of the electric motor and may be allowed to boil off asit takes up heat from the casing. Vapour formed by the cooling processmay be drawn off, compressed and cooled in suitable heat exchangeconfiguration or means to re-liquefy it. In these embodiments, theliquefied refrigerant is optionally a conventional refrigerant or, wherehigh-temperature superconducting coils are employed, liquid nitrogen. Incertain embodiment (not shown), a flow of a suitable liquid coolant maybe circulated through galleries formed in the casing walls and/orstators of the electric motor, heat taken up by the coolant subsequentlybeing dissipated via suitable air-cooled heat-exchange configuration ormeans.

In certain embodiments (not shown), the electric motor may be employedas an electrical generator and one or more of the operating principlesmay be employed to maximise electric power generation efficiency duringrapidly varying generating conditions. Such variable generatingconditions may be, for example, those experienced in environmentalsituations, such as wind power generation, tidal power generation andwave power generation.

In certain embodiments (not shown), where the electric motor is employedas a propulsion unit for an electric vehicle, it is optionallyincorporated into a wheel, it optionally drives a wheel via a rigid orarticulated shaft, it optionally drives a wheel via one or more chainsor belts, it is optionally fixed centrally to a vehicle and driveswheels to either side via articulated shafts, or it optionally generatesa flow of pressurised hydraulic fluid to power a hydraulic motor drivingone or more wheels.

Method of Design and Manufacture of Certain Exemplary Embodiments

The following examples are included to be illustrative of the variety ofdevices that may be designed and/or manufactures using certain disclosedembodiments. By using the approaches disclosed herein, it iscontemplated that a large number of devices may be designed andconstructed using the technology disclosed herein.

A. In this exemplary method of manufacture, one or more designrequirements are supplied. For example, these requirements mayincluding: size of the device, weight of the device, the maximum powerof the device, the voltage it needs to operate off or generate, the peakcurrent draw or supply (controls the maximum power), the number ofconnections to the power supply (DC, single phase, three phase), therange of angular velocities which the device will run at, the amount oftorque that needs to be delivered, the maximum torque the shaft needs tobe absorbed, or combinations thereof. It is to be understood that otherfeatures may be used in designing and manufacturing the device.

This information may then be processed in the following way: First asuitable module is selected such that it is capable of handling thevoltage required and has enough contacts and switches, (for example, twofor single phase and DC, three for three phase delta, four for threephase star). The power rating of each module is then divided into themaximum power required. The maximum size of the motor is then taken intoconsideration to decide the number of coils that can fit into a circulararrangement, this becomes the size of the platter. The number ofplatters is the number of coils per platter divided into the totalnumber of coils. This number of coils is then checked against themaximum angular velocity ensuring that the inductance of the coil in themodule is not such that it cannot switch at that desired frequency. Ifit is too high, the diameter can be reduced to result in less number ofcoils per platter, resulting in lower frequency of operation. Thisprovides the design information that may then be used to construct thedevice.

B. In this exemplary method of manufacture, one or more specificationsare provided. In this example, the device to be built specifies a motor300 kw as light as possible, preferably under 30 kgs, needs to fit intoa diameter less than 400 mm, as much torque as possible, needs toaccelerate smoothly from stationary, top angular velocity 3000 RPM, 120volts DC, peak current 1500 Amps. The device further specifies hightorque, and small size, and iron core, high power magnets. The DC sourceresults in two inputs.

The next step is to selected iron core 330 v, 90 A single phase modulewhich runs at 120 volts, max current of 90 A, peak power is 10 kw. Thisinformation indicates a minimum of 30 coils. To get maximum torquesmoothing, this specification would indicate one more magnet than coilper platter, Therefore, calculating the number of magnets that can bearranged in a circle of diameter of 400 mm, and find that up to 19 canfit. The magnets selected in this example are an even number so thatthey have alternating fields around the platter, with one less to makeit even, i.e., 18 magnets.

Next the number of coils is selected. In certain applications as in thisone, the number of coils is often a prime number to minimise harmonics,here 17 works, repetition every 34 rotations, harmonic at maximumangular velocity 1.5 Hz. The maximum frequency of switching coils atmaximum angular velocity is 50 rotations per second times 17 coils,divided by two to take into account positive and negative switch equals425 Hz.

This results in a final configuration of 2 stator platters of 17 coils,total 34 coils total of 320 kw (as one coil per platter is off at anypoint in time), and 3 platters of 18 magnets. Based on this design adevice may be built with a platter stator for coils accommodating 17coils. The next step is to design and manufacture magnetic platteraccommodating 18 coils and to design and manufacture an enclosure andbearing supports to hold the device together. Next assemble the coilsinto stator platters, magnets into rotor platters and build the device.The next step is to modify software to control 17 coils and to switch togeneration mode on breaking.

C. In this exemplary manufacture a specifications is set forth thatspecifies 3 MW, weight is not a consideration, needs to fit into adiameter less than 2000 mm, rotation up to 120 RPM, output voltageshould be 3000 volts RMS 650 Amps at 50 Hz to match mains, three phase.The specification further specifies high voltage at low speed, specifiesiron core, lots of windings, low current to optimise efficiency. Threephase source therefore specifies three outputs.

This indicates to select iron core 4000 v, 10 A three phase module. Runat 3000 volts, max current of 10 A, peak power is 30 kw. This alsoindicates a minimum of 100 coils. Furthermore, to maximise angularvelocity over the coils to maximise voltage generation, a large diameterplatter is well suited for this application. Since torque smoothness isnot of as much concern, but harmonics in large blades can be of concern,this example indicates one more magnet than coil per platter.

Based on this information, the next step is to calculate the number ofmagnets that can be arranged in a circle of diameter of 2000 mm, findthat up to 104 can fit. Since the number of coils is typically prime tominimise harmonics, 101 works in this example.

This results in a final configuration of, 1 stator platters of 101coils, and 2 platters of 102 magnets.

The next step is to design and manufacture platter stator for coilsaccommodating 101 coils. Design and manufacture magnetic plattersaccommodating 102 coils. Design and manufacture enclosure and bearingsupports to hold the device together. Assemble the coils into statorplatters, magnets into rotor platters and put it together. Modify thesoftware to control 101 coils and to synchronise to the grid and ensurevoltage is maintained at 3000V RMS.

D. In this exemplary example the specification specifies 1 GW, weightnot a problem, size not a problem, rotation up to 300 RPM, outputvoltage should be 3000 volts RMS 333333 Amps at 50 Hz primary driver ofmains frequency, three phase. There are not many constraints in thisspecification so it is possible to vary several parameters. However,this example uses the process outlined in example C. Another factor isto ensure that diameter is big enough for a shaft that is strong enoughto not shear when 1 GW of rotational power is being put into the shaft.This example may use 512 stacks of 101 coils, total modules 5221.

E. In this exemplary example the specification specifies 2 Kw, maxdiameter 400 mm, rotation up to 300 RPM, input voltage single phase 230v AC 50 hz, price constraint. Choose small modules, air core, 1 amps maxper coil. Total per coil 230 w, require about 10, pick 17 to ensure thatthe dead points in the single phase do not affect the overall poweroutput. To minimise cost combine switches and processor onto singlecircuit board and arrange coils around stator.

Applications

Certain embodiments may be used to convert electrical to mechanicalenergy. This may be used for traction. In certain embodiments, the motormay be mounted directly into a vehicle wheel housing for direct drive.See the photos shown in FIGS. 37 and 38. FIG. 36 illustrates anexemplary electrical machine that may be used in traction applications,further detail on this design can be found in FIG. 1. In certainembodiments, the electrical machine enclosure may have mounts thatpermit the enclosure to attach directly to suspension systems bysuitable fastenings and/or existing braking systems may be used aroundthe electrical machine. Directly attaching the motor to the wheel savesthe weight of drive shafts and possibly gearboxes and transmissions andis more efficient as it does not suffer the same mechanical losses ofsuch systems.

In an alternative embodiment (not shown), where the electric motor isemployed as a propulsion unit for an electric vehicle, it is optionallyincorporated into a wheel, it optionally drives a wheel via a rigid orarticulated shaft, it optionally drives a wheel via one or more chainsor belts, it is optionally fixed centrally to a vehicle and driveswheels to either side via articulated shafts, or it optionally generatesa flow of pressurised hydraulic fluid to power a hydraulic motor drivingone or more wheels.

Furthermore in certain applications, vehicles having electronic controlof braking and/or acceleration, opportunities exist for computer controlof vehicle dynamics, including one or more of the following:

Active cruise control, in which a vehicle maintains a predetermineddistance from a vehicle ahead;

Collision avoidance, where a vehicle brakes automatically to avoid acollision;

Emergency brake assistance, in which a vehicle senses an emergency stopand applies maximum effective braking;

Active software differentials, where individual wheel speed is adjustedin response to other inputs;

Active brake bias, where individual wheel brake effort is adjusted inreal time to maintain vehicle stability;

Brake steer, where individual wheel brake bias is adjusted to assiststeering; and

Sources of electric current, for traction applications, in sustained orintermittent.

Similarly, in other alternative embodiments, the magnets and theelectromagnetic coils may optionally be made in equal numbers, butpreferably with locational asymmetry to prevent or reduce magneticstasis at start-up. In certain applications, the greater centre diameterof the arrays of magnets and the electromagnetic coils, the greater thetorque able to be generated. The arrangement of the electric motorpermits many combinations to be created from standard components—from asingle rotor and stator combination to combinations employing at least10 rotors. The combinations employing larger numbers of rotors andstators may be used in large machines, such as heavy trucks andearthmoving equipment.

Certain embodiments are directed to electrical machines that may be usedin pump applications. These embodiments may be used in suitableapplications for such electrical machines. Certain embodiments disclosedherein may produce suitable high torque without the need for gearing,for example, pumps may be configured that move a large volume of waterat low velocities. By reducing the amount of inertia imparted to thewater, substantial less power is required to move the water.

Certain embodiments may be used as pool swim spas, as well as pumps forvarious applications in mining, chemical handling, and other applicationwhere large or other quantities of suitable solids, slurries, and/orliquids require to be moved at low speeds. FIG. 39 is a render of a pumpcomprising electrical machines, according to certain embodiments.

Certain embodiments are directed to linear solenoid configurations andrelated applications. These configurations may be used to convertelectrical energy into substantial linear motion. One advantage overtraditional solenoids is their ability to track desired positions and‘lock’ in place using built in feedback control per coil level. Theseembodiments may also include feedback control that may be used on one ormore of the coils. These configurations have similar power efficiencycharacteristics as discussed herein for other adaptive motorconfigurations. One application area is for power generation, e.g. wavemotions. FIG. 40 is a render of a single platter, single statorconfiguration. FIG. 41 is a schematic top view of the same design,indicating the positions of the magnets 94 and 95. FIG. 42 is aschematic isometric view. Shown in this view are the magnets 94 and 95mounted on the sliding magnet mount 99. The coils 88 are located insidethe stator 101 and not shown. An example positioning of the Coil ControlUnits and switching electronics can be seen at 129. As with the motorconfigurations disclosed herein, the linear configuration may beincreased in power by stacking further coil and/or magnet platters. Incertain embodiments, at least 2, 3, 4, 5, 6, 8, 10, 20 or more units maybe stacked. In certain embodiments, between 2 to 40, 2 to 10, 3, to 15,3 to 6, 4 to 8, 10 to 25, or other suitable ranges of stacked united maybe used in certain applications. Other uses of the linear configurationsdisclosed herein include: linear damper, linear spring/active suspensionsystem, actuators, conveyor belts, escalators, fans, 3 Phase forindustrial/mining and other, machinery (mining and industrial), and/ormagnetic inductive gearing.

Other applications may be regenerative braking and/or power generation.With respect to the renewable energy applications such as rotarymechanical energy applications, some applications are: wind powergeneration, hydro electricity generation, thermal power generationand/or thermal exchangers, and/or steam turbines.

FIG. 43 shows a schematic side view of a system that may be used in wavepower generation. This exemplary configuration of a wave generator usingfor example certain magnetic flux linear arrays disclosed herein is ableto be used for continuous (or substantially continuous, or partial)power generation. In FIG. 43, the one or more linear arrays 130 may beattached to floats 131 that float on or near the water surface 132. Thesystem may also be fixed to (or inserted partially into) to the floor133 of the body of water. The figure shows one linear array 134 at fullextension and two arrays 135 and 135 at full compression. As the wavepasses it causes the H shaped floats 131 to rise and fall. Differentconfigurations are contemplated, for example, a similar approach may beimplemented using a rotary axial flux generator and long arms withfloats attached. Certain embodiments are directed to a modular insertthat may be used for power generation and in certain aspects may besuitable for large scale power generation. As discussed herein one ofthe features of the design for certain electrical machines disclosed isthat each coil (or one or more coils) may have its own dedicated controlcircuitry. A coil and its supporting electronics may be incorporatedinto a small, hot swappable module. This is advantageous for on fieldassembly of large motors, and/or maintenance of large configurations(faulty coils and electronics may be replaced without full disassemblyof the motor).

An exemplary three phase, single platter, two megawatt, one hundred andone modules embodiment of the electrical machine is shown in FIGS. 44,45, 46, 47, and 48. Referring to FIG. 44 The design incorporates modules137, consisting of one coil 88, mounting rails 140, 141, 142, 143 whichalso connect the module to the shared electrical rails, and a handle 138to facilitate the easy removal or insertion of the module into thedevice. Each module may be self-contained. FIGS. 45 and 46 illustratethe positioning of the electronics contained inside the modules. Theelectronics are positioned on a circuit board 145. Power switches 111are positioned such that their solder tabs are attached 139 to the powerand mounting rails 144. Other electronics include power switches 112,microcontroller 79, isolated DC to DC converter and power supply 79,optical transceiver 119, and a Giant Magneto Resistive (GMR) positionsensor 121. In alternative embodiments, a variety of alternativerelative or absolute position sensors may be used.

FIG. 47 illustrates the sliders which connects the module to the 3 phaseshared rail and ground. Element 140 connects the module to ground, 141to the first phase, 142 to the second phase, 143 to the third phase.These sliders also permit the module to be inserted or removed from theelectrical machine either during operation or when the electricalmachine is stationary. The rails further facilitate the dissipation ofheat from the module to the electrical machine. FIG. 47B illustrates thedirection of insertion 146 into the electrical machines chassis.

FIG. 48 illustrates the electrical machine with 101 of the modulesinstalled, with the ground plate, mounting base and enclosure removedfor clarity. This configuration could be used for wind generationapplications. Some of the features include the modules illustrated inFIGS. 44 through 47, a series of annularly shaped rails 147 which areinsulated from each other using layers of insulation 148. The powerrails can be connected to multiple metal tabs 149, 150, 151. Two rotors8 with permanent magnets attached to their peripheries 5. Cut-outs 152in the middle of the rotor and stator save on material and weight whilemaintaining structural strength.

A series of light emitting diodes (LEDs) and optical sensors may bemounted on each (or one or more) module (not shown in FIG. 44) alignwith a section of the stator (not shown in FIG. 48) consisting of acoded regions of reflective and less reflective surfaces or holes. Whena module is powered up the microcontroller inside the module illuminatesthe LEDs, the sensors detect whether the coded region of the groundplate is a reflection or not from the ground plate. The microcontrolleruses the information from the sensors to create an address for use onthe communication bus, and to know its geometric position in the system.In alternative embodiments, the address can be hard coded in themicrocontroller, be set by a series of switches, jumpers, throughmagnetic switches, through bus probing or measuring the propagationdelay along a shared bus, and/or other suitable methods of allocatingaddresses to multimaster bus systems. This modular design ensures thatthe generator can maintain operation even if some of (or many of) themodules fail. Being able to replace the device during operation ensuredthat the electrical machine can keep operating for extended periods oftime that might otherwise require the generator to be shut down. Whenmodules fail, the module can communicate its failure to the maintainerof the electrical machine to instruct them to replace the module.Optional indicators on the module can assist in finding the faultymodule when the replacement is being made. As the modules may besufficiently small and/or light enough to carry, carrying replacementparts to and from hard to reach electrical machines, such as those in awind generator may be easily achieved. This is a useful advantage tocertain disclosed embodiments and improves repair and maintenance from atime and/or cost basis.

Certain disclosed embodiments of these generators may be linked togetherback to back on the same shaft, sharing rotors, increasing the powergeneration capabilities. The stacking of these generators results incertain advantages as disclose herein. A version of a 10 MW generator isillustrated in 49. These modular units 153 may be stacked to produceembodiments with multiple platters along one shaft 10 of enough strengthnot to shear when full power is applied to the shaft. The same powerrails 149 to 151 are used to connect to each generator in a line;however different conductors can be used to minimise resistive powerloss. Generators or motors may be custom designed to meet almost variouspower or size specifications. In certain embodiments, at least 2, 3, 4,5, 6, 7 8, 9, 10, 15, 20, 512, modular units may be combined. In certainembodiments between 2 to 40, 2 to 6, 3 to 9, 4 to 12, 5 to 16, 5 to 25,or 10 to 512 units may be combined.

Furthermore, adding a capacitor to the module, and configuring theswitches and the coil in either a buck, boost or a buck and boostconfiguration, the device may be driven by software to generate aspecific voltage at a specific frequency and may be connected directlyto the power grid without the need for step up or step downtransformers, adding considerable space and cost savings. Additionally,power generation may be stopped in software.

In certain embodiments, the torque required to turn the electricalmachine depends on the number of coils generating. The torque requiredto turn the machine may be in substantially real time (or real time)increased and/or decreased. When the shaft is being turned byfluctuating sources such as in wind generation, the electrical machinemay continually (or other suitable time periods) optimise the torquerequired to maintain a substantially uniform rotational velocity. Whenaccelerating from stationary the electrical machine may minimise thetorque required to start the device rotating.

Wind Turbines and other generators often require gearboxes to increasethe angular velocity of the shaft, such that the shaft is rotating at asufficiently high angular velocity to operate their generators atsufficiently high efficiency. As the rotor of certain embodiments of theelectrical machine disclosed herein has a suitably large radius therelative velocity at the edges of the device have enough velocity togenerate sufficient quantities of power as they pass by the coils.Inverters and other such controllers may not be required as thistechnology may be incorporated into the generator itself.

The following non-limiting examples further illustrate certainembodiments disclosed herein.

Example 1A.1

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one rotor with a plurality of magnetsattached to the at least one rotor, wherein the at least one module isin spaced relation to the plurality of the magnets; and the at least onerotor being in a rotational relationship with the at least one stator,wherein the quantity and configuration of the at least one module in theelectrical machine is determined based in part on one or more operatingparameters; wherein the at least one module is capable of beingindependently controlled; and wherein the at least one module is capableof being reconfigured based at least in part on one or more of thefollowing: at least one operating parameter during operation, at leastone performance parameter during operation, or combinations thereof.

Example 1A.2

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one slider with a plurality of magnetsattached to the at least one slider, wherein the at least one module isin spaced relation to the plurality of the magnets; and the at least oneslider being in a linear relationship with the at least one stator,wherein the quantity and configuration of the at least one module in theelectrical machine is determined based in part on one or more operatingparameters; wherein the at least one module is capable of beingindependently controlled; and wherein the at least one module is capableof being reconfigured based at least in part on one or more of thefollowing: at least one operating parameter during operation, at leastone performance parameter during operation, or combinations thereof.

Example 1A.3

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one slider with a plurality of magnetsattached to the at least one slider, wherein the at least one module isin spaced relation to the plurality of the magnets; and the at least onerotor being in a linear, substantially linear, circular, substantiallycircular, arced, substantially arced or combinations thereofrelationship with the at least one stator, wherein the quantity andconfiguration of the at least one module in the electrical machine isdetermined based in part on one or more operating parameters; whereinthe at least one module is capable of being independently controlled;and wherein the at least one module is capable of being reconfiguredbased at least in part on one or more of the following: at least oneoperating parameter during operation, at least one performance parameterduring operation, or combinations thereof.

Example 1A.4

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one platter or rotor with a pluralityof magnets attached to the at least one platter or rotor, wherein the atleast one module is in spaced relation to the plurality of the magnets;and the at least one platter or rotor being movement relationship withthe at least one stator, wherein the quantity and configuration of theat least one module in the electrical machine is determined based inpart on one or more operating parameters; wherein the at least onemodule is capable of being independently controlled; and wherein the atleast one module is capable of being reconfigured based at least in parton one or more of the following: at least one operating parameter duringoperation, at least one performance parameter during operation, orcombinations thereof.

Example 1A.5

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one platter or rotor with a pluralityof magnetic induction loops, attached to the at least one platter orrotor, wherein the at least one module is in spaced relation to theplurality of the magnetic induction loops; and the at least one platteror rotor being movement relationship with the at least one stator,wherein the quantity and configuration of the at least one module in theelectrical machine is determined based in part on one or more operatingparameters; wherein the at least one module is capable of beingindependently controlled; and wherein the at least one module is capableof being reconfigured based at least in part on one or more of thefollowing: at least one operating parameter during operation, at leastone performance parameter during operation, or combinations thereof.

Example 1A.6

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one platter or rotor with a pluralityof magnetic reluctance projections attached to the at least one platteror rotor, wherein the at least one module is in spaced relation of aplurality of magnetic reluctance projections; and the at least oneplatter or rotor being movement relationship with the at least onestator, wherein the quantity and configuration of the at least onemodule in the electrical machine is determined based in part on one ormore operating parameters; wherein the at least one module is capable ofbeing independently controlled; and wherein the at least one module iscapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, atleast one performance parameter during operation, or combinationsthereof.

Example 1A.7

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one rotor with a plurality of magnetsattached to the at least one rotor, wherein the at least one module isin spaced relation to the plurality of the magnets; and the at least onerotor being in a rotational relationship with the at least one stator.

Example 1A.8

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one slider with a plurality of magnetsattached to the at least one slider, wherein the at least one module isin spaced relation to the plurality of the magnets; and the at least oneslider being in a linear relationship with the at least one stator.

Example 1A.9

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one rotor with a plurality of magnetsattached to the at least one rotor, wherein the at least one module isin spaced relation to the plurality of the magnets; and the at least onerotor being in a linear, substantially linear, circular, substantiallycircular, arced, substantially arced or combinations thereofrelationship with the at least one stator.

Example 1A.10

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one platter or rotor with a pluralityof magnets attached to the at least one platter or rotor, wherein the atleast one module is in spaced relation to the plurality of the magnets;and the at least one platter or rotor being movement relationship withthe at least one stator.

Example 1A.11

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one platter or rotor with a pluralityof magnetic reluctance projections attached to the at least one platteror rotor, wherein the at least one module is in spaced relation to theplurality of magnetic reluctance projections; and the at least oneplatter or rotor being movement relationship with the at least onestator.

Example 1A.12

An electrical machine comprising: at least one stator at least onemodule, the at least one module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one platter or rotor with a pluralityof magnetic induction loops attached to the at least one platter orrotor, wherein the at least one module is in spaced relation to theplurality of magnetic induction loops; and the at least one platter orrotor being movement relationship with the at least one stator.

Example 2A.1

The electrical machine of one or more of the examples 1A.7 to 1A.12,wherein the quantity and configuration of the at least one module in theelectrical machine is determined based in part on one or more operatingparameters; wherein the at least one module is capable of beingindependently controlled; and wherein the at least one module is capableof being reconfigured based at least in part on one or more of thefollowing: at least one operating parameter during operation, at leastone performance parameter during operation, or combinations thereof.2A.2 The electrical machine of one or more of the examples 1A.7 to1A.12, wherein the quantity and configuration of the at least one modulein the electrical machine is determined based in part on one or moreoperating parameters. 2A.3 The electrical machine of one or more of theexamples 1A.7 to 1A.12, wherein the at least one module is capable ofbeing independently controlled. 2A.4 The electrical machine of one ormore of the examples 1A.7 to 1A.12, wherein the at least one module iscapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, atleast one performance parameter during operation, or combinationsthereof. 2A.5 The electrical machine of one or more of the examples 1A.7to 1A.12, wherein the quantity and configuration of the at least onemodule in the electrical machine is determined based in part on one ormore operating parameters; and wherein the at least one module iscapable of being independently controlled. 2A.6 The electrical machineof one or more of the examples 1A.7 to 1A.12, wherein the at least onemodule is capable of being independently controlled; and

wherein the at least one module is capable of being reconfigured basedat least in part on one or more of the following: at least one operatingparameter during operation, at least one performance parameter duringoperation, or combinations thereof. 2A.7 The electrical machine of oneor more of the examples 1A.7 to 1A.12, wherein the quantity andconfiguration of the at least one module in the electrical machine isdetermined based in part on one or more operating parameters; andwherein the at least one module is capable of being reconfigured basedat least in part on one or more of the following: at least one operatingparameter during operation, at least one performance parameter duringoperation, or combinations thereof.

3A The electrical machine of one or more of the above examples, whereinthe one or more operating parameters are selected from one or more ofthe following: maximum angular velocity, average angular velocity,minimum angular velocity, maximum power output, average power output,minimum power output, maximum input voltage, average input voltage,minimum input voltage, maximum generation voltage, average generationvoltage, minimum generation voltage, peak input current, average inputcurrent, minimum input current, maximum generation current, averagegeneration current, minimum generation current, maximum torque, averagetorque, activation sequence, minimum torque, torque smoothness, rate ofacceleration, accuracy of hold angle, minimising the variation ofangular velocity, rate of deceleration during breaking, diameter of theshaft, maximum radius of the electrical machine, maximum length of theelectrical machine, maximum depth of the electrical machine, maximumheight of the machine, maximum slide distance, minimum slide distance,maximum weight of the machine, minimum weight of the machine, maximumresistive power loss, unit redundancy and overall price.

4A.1 The electrical machine of one or more of the above examples,wherein the at least one operating parameter during operation may beselected from one or more of the following: maximum angular velocity,average angular velocity, minimum angular velocity, maximum poweroutput, average power output, minimum power output, maximum inputvoltage, average input voltage, minimum input voltage, maximumgeneration voltage, average generation voltage, minimum generationvoltage, shape and frequency of generated voltage, peak input current,average input current, minimum input current, maximum generationcurrent, average generation current, minimum generation current, maximumtorque, average torque, minimum torque, torque smoothness, activationsequence, rate of acceleration, order of accuracy of hold angle,minimising the variation of angular velocity, rate of decelerationduring breaking, diameter of the shaft, maximum radius of the electricalmachine, maximum length of the electrical machine, maximum depth of theelectrical machine, maximum height of the machine, maximum slidedistance, minimum slide distance, maximum weight of the machine, minimumweight of the machine, maximum resistive power loss, unit redundancy andoverall price. 4A.2 The electrical machine of one or more of the aboveexamples, wherein the at least one performance parameter duringoperation may be selected from one or more of the following: maximumangular velocity, maximum power output, deviation from output voltageduring generation, maintaining a required generation voltage, torquesmoothness, rate of acceleration, accuracy of hold angle, minimising thevariation of angular velocity, matching requested rate of decelerationduring breaking, minimising resistive power loss, overall efficiency,power factor correction, mechanical harmonic cancellation, electricalharmonic cancellation, accuracy of reproduced output voltage wave, andaccuracy of generated frequency. 4A.3 The electrical machine of one ormore of the above examples, wherein one or more performance parametersduring operation may be selected from one or more of the following:maximum angular velocity, maximum power output, deviation from outputvoltage during generation, maintaining a required generation voltage,torque smoothness, rate of acceleration, accuracy of hold angle,minimising the variation of angular velocity, matching requested rate ofdeceleration during breaking, minimising resistive power loss, overallefficiency, power factor correction, mechanical harmonic cancellation,electrical harmonic cancellation, accuracy of reproduced output voltagewave, and accuracy of generated frequency. 4A.4 The electrical machineof one or more of the above examples, wherein the at least one module iscapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation,wherein the at least one operating parameter during operation may beselected from one or more of the parameters listed in example 4A.3; atleast one performance parameter during operation, wherein the at leastone performance parameter during operation may be selected from one ormore of the parameter listed in example 4A.2; or combinations thereof.

5A The electrical machine of one or more of the above examples, whereinthe at least one electromagnetic coil comprises a plurality ofelectromagnetic coils that are in a substantially circular arrangementor an axial flux arrangement.

6A The electrical machine of one or more of the above examples, whereinthe at least one electromagnetic coil and the plurality of magnets arein an angular or a radially offset arrangement.

7A The electrical machine of one or more of the above examples, whereinthe number of coils in the at least one electromagnetic coil is not thesame number as the number of magnetic in the plurality magnets.

8A The electrical machine of one or more of the above examples, whereinthe number of coils in the plurality of electromagnetic coils is thesame number as the number of magnetic in the plurality of magnets andthe spaced relation between the plurality of electromagnetic coils andthe plurality of magnets is geometrically offset to prevent concentricalignment.

9A The electrical machine of one or more of the above examples, whereinthe number of coils in the at least one electromagnetic coil is at leastone less than the number of magnets in the plurality of magnets.

10A The electrical machine of one or more of the above examples, whereinthe plurality of electromagnetic coils are arranged in an axiallyaligned arrangement with the plurality of magnets.

11A The electrical machine of one or more of the above examples, whereinthe plurality of electromagnetic coils are arranged in axiallymisaligned arrangement by at least 5, 10, 15, 20, 25, 30, 35, 40, or 45degrees with the plurality of magnets.

12A The electrical machine of one or more of the above examples, whereinthe plurality of electromagnetic coils are axially aligned with the atleast one stator and the plurality of magnets are axially aligned withthe at least one rotor.

13A The electrical machine of one or more of the above examples, whereinthe plurality of electromagnetic coils are substantial perpendicular orperpendicular with the at least one stator and the plurality of magnetscoils are substantial perpendicular or perpendicular with the at leastone rotor.

14A The electrical machine of one or more of the above examples, furthercomprising an enclosure that is mechanically sufficient to suitablyresist deformation from mechanical forces when in operation.

15A The electrical machine of one or more of the above examples, furthercomprising an enclosure that is thermally conductive.

16A The electrical machine of one or more of the above examples, furthercomprising an enclosure that may be used as a conductor for one or moreelectronic switches.

17A.1 The electrical machine of one or more of the above examples,wherein the power to weight ratio of the electrical machine is at least5, 10, 20, 50, 100, 500, 1000 kilograms per kilowatts. 17A.2 Theelectrical machine of one or more of the above examples, wherein thepower to weight ratio of the electrical machine is at between 5 to 1000,5 to 10, 10 to 100, 10 to 500, 10 to 50, 20 to 1000, 20 to 50, 50 to100, 50 to 500, 100 to 500, or 500 to 1000 kilograms per kilowatts.

18A.1 The electrical machine of one or more of the above examples,wherein the power to weight ratio of the electrical machine is 10%, 25%,50%, 100%, 125%, 150%, 200%, 250%, 300%, 500%, 1000% greater than abrushless permanent magnet three phase electrical machine with asubstantially similar size and weight. 18A.2 The electrical machine ofone or more of the above examples, wherein the power to weight ratio ofthe electrical machine is between 10% to 1000%, 10 to 25%, 10% to 100%,25% to 50%, 25% to 150%, 50% to 250%, 50% to 100%, 100% to 125%, 100% to250%, 125% to 150%, 150% to 300%, 200% to 1000%, 250% to 500%, 250% to1000%, or 500% to 1000% greater than a brushless permanent magnet threephase electrical machine with a substantially similar size and weight.

19A.1 The electrical machine of one or more of the above examples,further comprising at least one sensor to detect absolute or relativeposition of the at least one rotor; and at least one control systemwhich, in response to inputs from the one or more of the following: theat least one sensor, at least one power command, at least one modecommand comprising one or more of the following: at least one drive,generate, braking and hold command, and at least one rotationaldirection command. 19A.2 The electrical machine of example 19A.1,wherein the at least one control system is configured to be in a driveconfiguration or has the at least one drive mode command, the at leastone control system activates at least one switch which energies one ormore of the magnetic coils to attract and repel the magnets for thepurpose of generating motion. 19A.3 The electrical machine of example19A.1, wherein the electrical machine is configured to be in ageneration configuration or has at least one mode command to generatepower, the at least one control system activates at least one switchwhich connects one or more coils to the external power rails. 19A.4 Theelectrical machine of example 19A.1, wherein the electrical machine isconfigured to be in a braking configuration or has the at least one modecommand to brake, the at least one control system activates at least oneswitch which connects one or more of the magnetic coils terminalstogether to oppose motion. 19A.5 The electrical machine of example19A.1, wherein the electrical machine is configured to be in a holdingconfiguration or has the at least one mode command to hold, the at leastone control system activates at least one switch energises one or moreof the magnetic coils to attract and repel magnets for the purpose ofstopping motion.

20A.1 The electrical machine of one or more of the above examples,wherein the at least one control system in operation is determining oneor more appropriately efficient modes of operation in relation to the atleast one operating parameter on a substantially continuous basis duringoperating periods. 20A.2 The electrical machine of one or more of theabove examples, wherein the at least one control system in operation isdetermining one or more appropriately efficient modes of operation inrelation to the at least one operating parameters, the at least oneperformance parameter or combinations thereof on a substantiallycontinuous basis during operating periods.

21A The electrical machine of one or more of the above examples, whereinthe electrical machine is capable of being operated efficiently over50%, 60%, 70%, 80%, 90%, 95%, 98%, or 100% of the RPM ranges of theelectrical machine.

22A.1 The electrical machine of one or more of the above examples,wherein the electrical machine has a power density of about 100, 500,1000, 2000, 5000, 10000, or 20000 kw/meter cubed. 22A.2 The electricalmachine of one or more of the above examples, wherein the electricalmachine has a power density of at least 100, 500, 1000, 2000, 5000,10000, or 20000 kw/meter cubed. 2A.3 The electrical machine of one ormore of the above examples, wherein the electrical machine has a powerdensity of between 100 to 20,000, 100 to 200, 100 to 500, 250 to 500,500 to 1000, 500 to 2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000,5000 to 10,000, 5000 to 15,000, or 10,000 to 20,000 kw/meter cubed.

23A.1 The electrical machine of one or more of the above examples,wherein one or more of the at least one operating parameter of theelectrical machine may be reconfigured in substantially real time. 23A.2The electrical machine of one or more of the above examples, wherein oneor more of the at least one operating parameter, the at least oneperformance parameter or combinations thereof of the electrical machinemay be reconfigured in substantially real time.

24A The electrical machine of one or more of the above examples, whereinthe at least one control system provides individual control over atleast 30%, 40%, 50%, 60%, 70% 80%, 90%, 95% or 100% of the plurality ofcoils.

25A The electrical machine of one or more of the above examples, whereinthe at least one operating parameter of the electrical machine may bereconfigured in substantially real time and the optimal settings forperformance determined and implemented across 50%, 60%, 70%, 80%, 90%,95%, 98%, or 100% of one or more of the following: operating speeds andloads.

26A.1 The electrical machine of one or more of the above examples,wherein the timing of the plurality of coils may be reconfigured insubstantially real time in order to continuously optimize the timing ofthe plurality of coils. 26A.2 The electrical machine of one or more ofthe above examples, wherein the timing of the at least one coil may bereconfigured in substantially real time in order to continuouslyoptimize the timing of the at least one of coil.

27A.1 The electrical machine of one or more of the above examples,wherein the total number of permanent magnets may be reduced by aminimum of 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60% or 70%and still provide comparable power output to a brushless permanentmagnet three phase electrical machine. 27A.2 The electrical machine ofone or more of the above examples, wherein the total number of permanentmagnets may be reduced by a minimum of between 10% to 70%, 10% to 25%,20% to 50%, 15% to 35%, 20% to 55%, 25% to 50%, 30% to 60%, 35% to 50%,40% to 60%, 45% to 70%, or 50% to 70%, and still provide comparablepower output to a brushless permanent magnet three phase electricalmachine.

28A.1 The electrical machine of one or more of the above examples,wherein the plurality of coils has about 1000, 500, 100, 50, 40, 35, 3025, 20, 15, 10, 5, times less variation in torque through a rotationthan a brushless permanent magnet three phase electrical machine withcomparable power output. 28A.2 The electrical machine of one or more ofthe above examples, wherein the plurality of coils has between 1000 to100, 1000 to 100, 500 to 100, 500 to 20, 100 to 5, 100, to 30, 50 to 10,40 to 15, 35 to 10, 30 to 15, 25 to 10, 20 to 5, 15 to 5, or 10 to, 5,times less variation in torque through a rotation than a brushlesspermanent magnet three phase electrical machine with comparable poweroutput.

29A.1 The electrical machine of one or more of the above examples,wherein the material savings in the magnets would be at least 10%, 15%,20%, 30%, 40%, 50%, or 60% of a brushless permanent magnet permanentmagnet three phase electrical machine with comparable power output.29A.2 The electrical machine of one or more of the above examples,wherein the material savings in the magnets would be between 10% to 60%,10% to 30%, 15% to 30%, 20% to 50%, 30% to 50%, 40% to 60%, or 50% to70% of brushless permanent magnet three phase electrical machine withcomparable power output.

30A.1 The electrical machine of one or more of the above examples,wherein the material savings in the copper would be at least 10%, 15%,20%, 30%, 40%, 100%, 200%, 1000% more than that of a similar brushlesspermanent magnet 3 phase electrical machine with similar resistive powerloss per power output. 30A.2 The electrical machine of one or more ofthe above examples, wherein the material savings in the copper would bebetween 10% to 100%, 15% to 40%, 20% to 100%, 20% to 200%, 30% 1000%,40% to 150%, 100% to 200%, 200% to 500%, 200% to 1000%, 500% to 1000%more than that of a similar brushless permanent magnet 3 phaseelectrical machine with similar resistive power loss per power output.

31A The electrical machine of one or more of the above examples, whereinthe stator can be manufactured out of aluminium, steel, copper,polyethylene, acrylic, polymer reinforced carbon fibre, polymerreinforced fiberglass, other metallic, plastic and/or compositematerials or combinations thereof, and the stator has suitable rigidity.

32A The electrical machine of one or more of the above examples, whereinthe rotor can be manufactured out of aluminium, steel, copper,polyethylene, acrylic, polymer reinforced carbon fibre, polymerreinforced fiberglass, other metallic, plastic and/or compositematerials or combinations thereof and the rotor has suitable rigidity.

33A The electrical machine of one or more of the above examples, whereinthe enclosure can be manufactured out of aluminium, steel, copper,polyethylene, acrylic, polymer reinforced carbon fibre, polymerreinforced fiberglass, other metallic, plastic and/or compositematerials or combinations thereof and the enclosure has suitablerigidity.

34A The electrical machine of one or more of the above examples, whereinthe magnetic field in the rotor or slider can be produced through theuse of rare earth or other conventional forms of permanent magnets.

35A The electrical machine of one or more of the above examples, whereinthe plurality magnetic field generators are one or more of thefollowing: loops or coils of a metallic material that induce a currentin the loops to produce a magnetic field.

36A The electrical machine of one or more of the above examples, whereinthe plurality magnetic field generators are strips of ferromagneticmaterial that redirect magnetic fields.

37A.1 The electrical machine of one or more of the above examples,wherein to save space, cost or both, the at least one switches for theat least one module is fabricated on the same circuit board. 37A.2 Theelectrical machine of one or more of the above examples, wherein, the atleast one switch for the at least one module is fabricated on the samecircuit board.

38A.1 The electrical machine of one or more of the above examples,wherein to save space, cost or both, at least one electromagnetic coilof the at least one module is fabricated as a single unit. 38A.2 Theelectrical machine of one or more of the above examples, wherein the atleast one electromagnetic coil of the at least one module is fabricatedas a single unit.

39A The electrical machine of one or more of the above examples, whereinthe at least one module has an enclosure that may be attached to one ormore other modules in order to construct the at least one stator withouthaving to have a separate stator structure.

40A The electrical machine of one or more of the above examples, whereinone or more of the plurality of magnets have an enclosure around themsuch that one or more of the magnets may be attached to one or moreother magnets to create at least one rotor that may be connected to atleast one shaft.

41A The electrical machine of one or more of the above examples, whereinthe physical location of the at least one module in reference to theother modules and the at least one stator is hard coded into the controlsoftware. 42A The electrical machine of one or more of the aboveexamples, wherein the physical location of the at least one module inreference to one or more of the other modules and the at least onestator is encoded by one or more sequences of electrical connectionsthat may be constructed using switches, solder bridges, jumpers, cuttingprinted circuit tracks, other suitable ways of making and breakingelectrical connections, or combinations thereof.

43A The electrical machine of one or more of the above examples, whereinthe physical location of the at least one module in reference to one ormore of the other modules and the at least one stator is detected by thelocation that the at least one module is inserted into in the at leastone stator by a series of electrical contacts, optical reflections,magnetic forces or combinations thereof encoding the position of themodule.

44A The electrical machine of one or more of the above examples, thatare one or more combinations of examples 41A, 42A and 43A.

45A The electrical machine of one or more of the above examples, whereinthe at least one electromagnetic coil is arranged around the peripheryof the at least one stator.

46A The electrical machine of one or more of the above examples, furthercomprising at least one shaft.

47A The electrical machine of one or more of the above examples, whereinthe plurality of magnets are arranged around the periphery of the atleast one rotor and have substantially the same centre diameter as thatof one or more of the at least one electromagnetic coil, a plurality ofthe at least one electromagnetic coils, or a substantial portion of theplurality of the at least one electromagnetic coils.

49A The electrical machine of one or more of the above examples, whereinthe plurality of magnets are arranged around the periphery of the atleast one rotor and have substantially the same centre diameter as thatof one or more of the at least one electromagnetic coil, a plurality ofthe at least one electromagnetic coils, or a substantial portion of theplurality of the at least one electromagnetic coils and two or more ofthe magnets have alternating pole orientation.

50A The electrical machine of one or more of the above examples, whereintwo or more of the magnets of the plurality of magnets have alternatingpole orientation.

51A The electrical machine of one or more of the above examples, whereinthere is a gap between the at least one stator and the at least onerotor.

52A.1 The electrical machine of one or more of the above examples,wherein the relative weight of the at least one electromagnetic coil isapproximately equal to an inverse of the total number of coils ascompared to a single phase electrical machine with a substantiallysimilar resistive loss. 52A.2 The electrical machine of one or more ofthe above examples, wherein the electrical machine has (n) coils and aweight of approximately 1/(n−1) to 1/(n+1) relative to a single phasemotor with substantially the similar resistive loss.

53A.1 The electrical machine of one or more of the above examples,wherein one or more module coil activation sequences are computed duringoperation of the electrical machine and the order of the at least onemodule activating being sequentially based on its geometric position ina module array. 53A.2 The electrical machine of one or more of the aboveexamples, wherein the module coil activation sequence is computed duringmachine operation the order of modules activating being sequentiallybased on their geometric position in the module array.

54A.1 The electrical machine of one or more of the above examples,wherein the one or more module coil activation sequence is computedduring electrical machine operation, the order of at least one moduleactivating being based at least in part on sensor feedback. 54A.2 Theelectrical machine of one or more of the above examples, wherein themodule coil activation sequence is computed during machine operation,the order of modules activating being based upon sensor feedback.

55A.1 The electrical machine of one or more of the above examples,wherein the module coil activation sequence is computed during machineoperation, the order of modules activating being determined by asequence pattern. 55A.2 The electrical machine of one or more of theabove examples, wherein the module coil activation sequence is computedduring machine operation and the order of the at least one modulesactivating being determined by at least in part one or more sequencepatterns.

56A.1 The electrical machine of one or more of the above examples,wherein the module coil activation sequence is computed during machineoperation and the order of modules activating being determined based atleast in part on one or more optimal power usage scenarios. 57A.2 Theelectrical machine of one or more of the above examples, wherein themodule coil activation sequence is predetermined and stored, and thesequence is sourced at least in part from sensor feedback.

58.A.1 The electrical machine of one or more of the above examples,wherein the module coil activation sequence is predetermined and stored,the nature of the sequence being sourced from precomputed data storedwithin the module.

58.A.2 The electrical machine of one or more of the above examples,wherein the module coil activation sequence is predetermined and stored,and the nature of the sequence being sourced at least in part fromprecomputed data stored within the module.

59A.1 The electrical machine of one or more of the above examples,wherein the module coil activation sequence is predetermined and stored,the nature of the sequence being sourced from external modules over acommunications bus. 59A.2 The electrical machine of one or more of theabove examples, wherein the module coil activation sequence ispredetermined and stored, and the nature of the sequence being sourcedfrom one or more external modules over one or more communicationsbusses.

60A The electrical machine of one or more of the above examples, whereinthe module coil activation sequence is determined based on one or moreof the above examples, sourced based on one or more of the aboveexamples or both.

61A.1 The electrical machine of one or more of the above examples thetotal number of powered coils in the active sequence can vary duringoperation from the total number of coils, to none. 61A.2 The electricalmachine of one or more of the above examples, wherein the total numberof the at least one electromagnetic coils powered in the active sequencemay vary during operation from the total number of coils, to none.

62A The electrical machine of one or more of the above examples, whereinthe number of the at least one electromagnetic coils active may or maynot be based upon sensor feedback.

63A The electrical machine of one or more of the above examples, whereinthe control of the electrical machine is centralised on at least onecontrol module.

64A The electrical machine of one or more of the above examples, whereinthe control of the electrical machine is distributed to one or more ofthe modules, with one or more modules acting independently.

65A The electrical machine of one or more of the above examples, whereinthe control of the electrical machine is arbitrated between two or moredesignated modules.

66A The electrical machine of one or more of the above examples, whereinone or more modules may be individually removed, added, or replacedduring operation of the machine, without substantially affecting theoperational state of the machine.

67A The electrical machine of example 66A, wherein 1, 2, 3, 4, 5, 6, 7,8, 9, or 10 modules may be individually removed, added, or replacedduring operation of the machine, without substantially affecting theoperational state of the machine.

68A The electrical machine of example 66A, wherein 1, 2, 3, 4, 5, 6, 7,8, 9, or 10 modules may be individually removed, added, or replacedduring operation of the machine, without substantially affecting theoperational state of the machine.

69A The electrical machine of one or more of the above examples, whereinone or more of the at least one modules may be individually removed,added, or replaced while the machine is powered off.

70A The electrical machine of one or more of the above examples, whereinone or more of the at least one operational parameter used by individualmodules are tuned dynamically during operation of the electricalmachine, based at least in part on sensor feedback.

71A The electrical machine of one or more of the above examples, whereinone or more of the at least one operational parameter used by individualmodules are tuned dynamically during operation of the electricalmachine, and the tuning methods used may or may not involve the use ofmachine learning algorithms.

72A The electrical machine of one or more of the above examples, whereinthe machines control system permits the motor to operate in both theclockwise and counterclockwise direction with respect to the rotationalaxis of the primary output or input.

73A The electrical machine of one or more of the above examples, whereinone or more of the at least one modules further comprises one or moresafety systems implemented in hardware, software, or both to allowautomatic power cut-off with respect to the coil, in the event of afeedback based event.

74A The electrical machine of one or more of the above examples, whereinone or more of the at least one modules further comprises one or moreexternal power safety cut-off control inputs on one or more of themodules. The inputs taking the form of tactile switches or digital touchpanels or communications buses, the cut offs being designed such thatthey bypass the primary controller in each module.

75A The electrical machine of one or more of the above examples, whereinone or more of the at least one modules further comprises one or moreexternal power safety cut-off control inputs on one or more of themodules and the inputs may be one or more of the following: tactileswitches, digital touch panels, communications buses, or combinationsthereof, wherein the cut offs are designed such that they bypass theprimary controller in one or more of the at least one module.

76A The electrical machine of one or more of the above examples, whereinthe at least one module further comprises at least one sensor fordetecting the back EMF from the modules coil in order to reduce coggingeffects to improve efficiency, and the back-EMF of an unpowered coil isrecorded at a representative range of speeds using theanalogue-to-digital converter in at least one coil control unit duringoperation; the un-powered coil is then powered to a voltage thatsubstantially negates the back-EMF thereby neutralizing the magneticinteraction between the un-powered coil and the magnets; and optionalthis procedure may be repeat for one or more coils in the array in orderto reduce cogging effects.

77A Any of the above examples implemented in hardware, software, orcombinations thereof.

78A The electrical machine of one or more of the above examples, whereinthe at least one module further comprises one or more sensors fordetecting the voltage across the at least one module's coil.

79A The electrical machine of one or more of the above examples, whereinthe at least one module further comprises one or more sensors fordetecting the current flowing across the at least one module's coil.

80A The electrical machine of one or more of the above examples, whereinthe at least one module further comprises one or more sensors fordetecting the back EMF from the at least one module's coil.

81A The electrical machine of one or more of the above examples, whereinthe at least one module further comprises one or more sensors fordetecting the absolute or relative position of the machine's the atleast one rotor in relation to the at least one module's position.

82A The electrical machine of one or more of the above examples, whereinthe at least one module further comprises one or more sensors fordetecting the velocity of the machines the at least one rotor inrelation to the at least one module's position.

83A The electrical machine of one or more of the above examples, whereinthe at least one module further comprises one or more sensors fordetecting the thermal temperature around the at least one module orother surfaces within the electrical machine.

84A The electrical machine of one or more of the above examples, whereinthe at least one module further comprises one or more sensors fordetecting one or more of the following: the magnitude, the angle and thedirection of at least one magnetic field.

85A The electrical machine of one or more of the above examples, whereinthe at least one module further comprises one or more sensors fordetecting accelerations, for the purpose of vibration detection.

86A A method of use that uses the electrical machine of one or more ofthe above examples or combinations of the features disclosed herein.

87A A system that uses the electrical machine of one or more of theabove examples or combinations of the features disclosed herein.

88A A module that incorporates the features of one or more of the aboveexamples or combinations of the module features disclosed herein.

89A A control systems for an electrical machine that incorporates thefeatures of one or more of the above examples or combinations of thecontrol features disclosed herein.

90A A control systems for a module that incorporates the features of oneor more of the above examples or combinations of the control featuresdisclosed herein.

91A The electrical machine of one or more of the above examples, whereinat least one adaptive control is implemented by performing optimisationduring machine operation through the use of one or more of thefollowing: at least one support vector machine, neural networkalgorithm, a fuzzy logic algorithm, of machine learning algorithms andthrough the use of other suitable adaptive control techniques.

The present disclosure should be taken to include feasible combinationsof features described herein.

The combination of features described is such as to allow the electricmotor to operate efficiently over a wide power and RPM range and, whererequired, with high power and torque density. Additionally, it permitscombinations of standard components to be assembled together to providea range of electric motor configurations.

The exemplary approaches described may be carried out using suitablecombinations of software, firmware and hardware and are not limited toparticular combinations of such. Computer program instructions forimplementing the exemplary approaches described herein may be embodiedon a tangible, non-transitory, computer-readable storage medium, such asa magnetic disk or other magnetic memory, an optical disk (e.g., DVD) orother optical memory, RAM, ROM, or any other suitable memory such asFlash memory, memory cards, etc.

Additionally, the disclosure has been described with reference toparticular embodiments. However, it will be readily apparent to thoseskilled in the art that it is possible to embody the disclosure inspecific forms other than those of the embodiments described above. Theembodiments are merely illustrative and should not be consideredrestrictive. The scope of the disclosure is given by the appendedclaims, rather than the preceding description, and variations andequivalents that fall within the range of the claims are intended to beembraced therein.

The invention claimed is:
 1. An electrical machine comprising: at leastone stator; and at least one module, the at least one module comprisingat least one electromagnetic coil and at least one switch, the at leastone module being attached to the at least one stator; wherein thequantity and configuration of the at least one module in the electricalmachine is determined based in part on one or more operating parameters;wherein the at least one module is capable of being independentlycontrolled; wherein the at least one module is capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, at least one performanceparameter during operation, or combinations thereof; and wherein aphysical location of the at least one module in reference to one or moreof the other modules and the at least one stator is detected by thelocation that the at least one module is inserted into in the at leastone stator by a series of electrical contacts, optical reflections,magnetic forces or combinations thereof encoding the position of themodule.
 2. The electrical machine of claim 1, further comprising one ofthe following: at least one rotor with a plurality of magnets attachedto the at least one rotor, wherein the at least one module is in spacedrelation to the plurality of the magnets and the at least one rotorbeing in a rotational relationship with the at least one stator, atleast one slider with a plurality of magnets attached to the at leastone slider, wherein the at least one module is in spaced relation to theplurality of the magnets; and the at least one slider being in a linearrelationship with the at least one stator, or at least one platter orrotor with a plurality of magnets attached to the at least one platteror rotor, wherein the at least one module is in spaced relation to theplurality of the magnets; and the at least one platter or rotor beingmovement relationship with the at least one stator.
 3. The electricalmachine of claim 2, wherein the at least one operating parameter duringoperation may be selected from one or more of the following: maximumangular velocity, average angular velocity, minimum angular velocity,maximum power output, average power output, minimum power output,maximum input voltage, average input voltage, minimum input voltage,maximum generation voltage, average generation voltage, minimumgeneration voltage, shape and frequency of generated voltage, peak inputcurrent, average input current, minimum input current, maximumgeneration current, average generation current, minimum generationcurrent, maximum torque, average torque, minimum torque, torquesmoothness, activation sequence, rate of acceleration, order of accuracyof hold angle, minimising the variation of angular velocity, rate ofdeceleration during breaking, diameter of the shaft, maximum radius ofthe electrical machine, maximum length of the electrical machine,maximum depth of the electrical machine, maximum height of the machine,maximum slide distance, minimum slide distance, maximum weight of themachine, minimum weight of the machine, maximum resistive power loss,and unit redundancy and overall price.
 4. The electrical machine ofclaim 2, wherein the at least one performance parameter during operationmay be selected from one or more of the following: maximum angularvelocity, maximum power output, deviation from output voltage duringgeneration, maintaining a required generation voltage, torquesmoothness, rate of acceleration, accuracy of hold angle, minimising thevariation of angular velocity, matching requested rate of decelerationduring breaking, minimising resistive power loss, overall efficiency,power factor correction, mechanical harmonic cancelation, electricalharmonic cancelation, accuracy of reproduced output voltage wave, andaccuracy of generated frequency.
 5. The electrical machine of claim 2,wherein the power to weight ratio of the electrical machine is atbetween 5 to 1000, 5 to 10, 10 to 100, 10 to 500, 10 to 50, 20 to 1000,20 to 50, 50 to 100, 50 to 500, 100 to 500, or 500 to 1000 grams perkilowatts.
 6. The electrical machine of claim 2, further comprising atleast one sensor to detect absolute or relative position of the at leastone rotor; and at least one control system which, in response to inputsfrom the one or more of the following: the at least one sensor, at leastone power command, at least one mode command comprising one or more ofthe following: at least one drive, generate, braking and hold command,and at least one rotational direction command.
 7. The electrical machineof claim 6, wherein the at least one control system is configured to bein a drive configuration or has the at least one drive mode command, theat least one control system activates at least one switch which energiesone or more of the magnetic coils to attract and repel the magnets forthe purpose of generating motion.
 8. The electrical machine of claim 6,wherein the electrical machine is configured to be in a generationconfiguration or has at least one mode command to generate power, the atleast one control system activates at least one switch which connectsone or more coils to the external power rails.
 9. The electrical machineof claim 6, wherein the electrical machine is configured to be in abraking configuration or has the at least one mode command to brake, theat least one control system activates at least one switch which connectsone or more of the magnetic coils terminals together to oppose motion.10. The electrical machine of claim 6, wherein the electrical machine isconfigured to be in a holding configuration or has the at least one modecommand to hold, the at least one control system activates at least oneswitch energises one or more of the magnetic coils to attract and repelmagnets for the purpose of stopping motion.
 11. The electrical machineof claim 2, wherein the at least one control system in operation isdetermining one or more appropriately efficient modes of operation inrelation to the at least one operating parameters, the at least oneperformance parameter or combinations thereof on a substantiallycontinuous basis during operating periods.
 12. The electrical machine ofclaim 2, wherein the electrical machine has a power density of between100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000to 15,000, or 10,000 to 20,000 kw/meter cubed.
 13. The electricalmachine of claim 2, wherein one or more of the at least one operatingparameter, the at least one performance parameter or combinationsthereof of the electrical machine may be reconfigured in substantiallyreal time.
 14. The electrical machine of claim 2, wherein the at leastone control system provides individual control over at least 30%, 40%,50%, 60%, 70% 80%, 90%, 95% or 100% of the plurality of coils.
 15. Theelectrical machine of claim 2, wherein the module coil activationsequence is computed during machine operation the order of modulesactivating being sequentially based on their geometric position in themodule array.
 16. The electrical machine of claim 2, wherein the modulecoil activation sequence is computed during machine operation, the orderof modules activating being based upon sensor feedback.
 17. Theelectrical machine of claim 2, wherein the module coil activationsequence is computed during machine operation and the order of the atleast one modules activating being determined by at least in part one ormore sequence patterns.
 18. The electrical machine of claim 2, whereinthe total number of the at least one electromagnetic coils powered inthe active sequence may vary during operation from the total number ofcoils, to none.
 19. The electrical machine of claim 2, wherein thecontrol of the electrical machine is centralised on at least one controlmodule.
 20. The electrical machine of claim 2, wherein one or moremodules may be individually removed, added, or replaced during operationof the machine, without substantially affecting the operational state ofthe machine.